In-Plant Training Report at Allahabad Canning Limited

IN-PLANT TRAINING
at
MORTON INDIA
ALLAHABAD CANNING LIMITED
BAMRAULI, ALLAHABAD
UTTAR PRADESH
AN ISO 9001:2015, ISO 22000:2005, FSSAI REGISTERED INDUSTRY
(FROM 1ST
TO 30TH
JUN ‘18)
Report submitted
by
ABDUL REHMAN
B TECH. FOOD TECHNOLOGY
SAM HIGGINBOTTOM UNIV. OF AGRICULTURE, TECHNOLOGY & SCIENCES
(FORMERLY ALLAHABAD AGRICULTURAL INSTITUTE)
ALLAHABAD
Under the guidance
of
MR. G. N. SHUKLA
HEAD, PRODUCTION UNIT
ALLAHABAD CANNING LIMITED
ADDRESS: P.O. BAMRAULI, ALLAHABAD
E MAIL: accos@sancharnet.in
PHONE: + 91 532 258 0042

3
ACKNOWLEDGEMENTS
It is with immense pleasure I took the opportunity to express my deep sense
of gratitude and sincere thanks to all the people whose combined efforts results in
completion of the training session.
To start with, I would like to present my deep gratitude to Mr. G. N.
Shukla (Production Head, Allahabad Canning Ltd.) who reposed faith in me
and gave the opportunity to gain practical experience by working in the esteemed
organization.
I am grateful to Mr. S. S. Tomar (Production In-charge) & Mr. Keshav
Pandey (Head, Quality Assurance) who took time from their busy schedule to
answer the queries & giving their noble assistance.
I would like to present my gratitude and thanks to Mr. Alok Pandey, Mr.
Dubey, Mrs. Maya & others for giving us their valuable inputs which helped a
lot in successful completion of training work.
I am highly indebted towards Prof. Suvrat Kumar Singh (Head, Dept of
FPE, SHUATS) for arranging the training programme through his hardened
efforts and constant motivation during the entire session.
Lastly, I would also like to thank my parents for their blessings, love and
support without which I could not have reached this stage.
ABDUL REHMAN
(16BTFT070)

4
INDEX
S. NO. DESCRIPTION PG NO.
PART I- INTRODUCTION
1. K. K. BIRLA GROUP OF SUGAR INDUSTRIES: A Short Description 6
2. About Allahabad Canning Limited 7
3. Infrastructure: Allahabad Canning Limited 9
4. Birla Morton Product’s Description 11
PART II- PROCESSING
5. Mango Products
-Mango Slice
-Mango Pulp
13
6. Litchi Product
-Litchi Whole
17
7. Tomato Products
-Tomato Paste
-Tomato Puree
-Tomato Ketchup
-Baked Beans in Tomato Sauce
20
8. Cherry Product
-Cherry Whole
26
9. Sauces
-Green Chilli Sauce
-Red Chilli Sauce
-Soya Sauce
29
10. Jam, Jelly & Marmalade
-Apricot Jam
-Mix Fruit Jam
-Pineapple Jam
-Strawberry Jam
-Guava Jelly
-Orange Marmalade
33
11. Pickle
-Green Mango Pickle
41
12. Drinks
-Mango
-Litchi
-Pineapple
-Mix Fruit
42

5
-Mango Panna
-Lime Juice Cordial
13. Crush & Squash
-Orange Crush
-Lemon Squash
49
PART III- LABORATORY TESTING PARAMETERS
14. Internal Testing at Quality Assurance Lab, Allahabad Canning Ltd.
-Internal and External condition of Can
-Pressure Test on Cans
-Determination of Soluble Solids
-Determination of pH value
-Test for consistency (using Bostwick Consistometer)
-Determination of acidity
-Determination of Sulphur dioxide
52
PART IV- MACHINERIES & EQUIPMENTS
15. Equipments at Allahabad Canning Ltd.
-Induction Cap Sealer
-Peeler Machine
-Laser Marking Machine
-Blister Packaging Machine
-Vegetable Slicing Machine
-Crown Corking Machine
-Can Manufacturing equipments (Reformer, Flanger, Seamer, Exhaust box, Retort)
-Steam Jacketed Kettle
56
PART V- UTILITIES
16. Boiler at Allahabad Canning Ltd. 68
17. Waste Water Treatment Plant at Allahabad Canning Ltd. 70
18. REFERENCES

6
KK BIRLA GROUP OF SUGAR INDUSTRIES:
A Short description
The company also had plant for production of industrial alcohol on commercial basis
with its several operational units all over the country. Through its network of three
distilleries, it has the capacity to process around 2,60,000 litres of industrial alcohol
daily.
The sugar industry is a critical part of the rural economy in India as over 50 million
farmers are regular suppliers to this industry. The K K Birla Group of sugar companies
purchases its sugarcane from over 321,000 farmers and directly employs about 6,000
workers in its seven plants. The Group plays an important and constructive role in the
social development and the general upliftment of the people in its command areas.
Demonstration camps for better farming methodologies, technical seminars, subsidies for
better quality seeds, research into high yielding and high sucrose varieties of sugarcane,
loans to farmers are some of the ways in which the Group tries to play its role in helping
the society at large. Beside this, the Group has also built schools where job oriented
education is provided at concessional fees and hospitals, temples, etc. have been built
near its plants for use by the society at large.
The K.K. Birla Group of sugar companies is
one of the largest players in the Indian private
sector with a cane crushing capacity of around
47,000 tonnes daily. The Group produces
white crystal sugar and various by-products
through its network of highly efficient seven
plants located in the states of Uttar Pradesh
and Bihar in northern India.
The industry first entered into the sugar
business in 1932 and with rich experience it is
today one of the leading sugar manufacturers
in the Country and amongst the fastest
growing sugar and allied products producing
industrial conglomerate. Apart from sugar, the
K K Birla Group of sugar companies also is a
leading producer of industrial alcohol
(including ethanol) co-generation of renewable
energy, processed food products and Tea.

7
ABOUT ALLAHABAD CANNING LIMITED
The canned fruit/food processing unit named and known as Allahabad Canning
Company and a division of Allahabad Canning Limited is situated at Village: Bamrauli
is on the outskirts of the city of Allahabad in the State of Uttar Pradesh. It is 10 km away
from Allahabad railway station and is connected by one furlong approach road to the
main Grand Trunk Road connecting Delhi and Kolkata. The unit has an area of 53486.58
Sq.mtr. Under the trade name MORTON the units produces all types of Canned Fruits &
Vegetables, Jams, Jellies, Marmalades, Juices, Tomato Products (like Tomato Ketchup,
Baked Beans in Tomato Sauce, Tomato puree), Vegetables Sauces, Squashes etc. It also
produces breakfast cereals like cornflakes, chocos, white oats and antacids. The
Production is carried out under strict hygienic condition & under the supervision of
qualified food technologists. The R&D department here, is always striving to develop
new products and packaging to the utmost satisfaction of its consumers.
The distribution net work of the Unit is spread through 32 depots which service 910
distributors. A strong sales team with more than 65 executives is headed by the
Executive President- Sales and Marketing. The wide distribution network is available for
Retail, HoReCa and institutes.
File Photo: Entrance Gate Allahabad Canning Ltd.

8
File Photo: Delivery Truck ready to be dispatched at Allahabad Canning Ltd.
The Morton brand has been registered in the Country since 1947. The Morton Brand has
been purchased by The Oudh Sugar Mills Limited - Registered office - Hargaon-261121,
Sitapur (U.P). Allahabad Canning Limited was established in 1959 as one of the largest
and dynamic industrial group of “Dr K.K.Birla”, with Shri C.S.Nopany as the Chairman
cum Managing Director. Board of Directors consists of eminent personalities of India.
Day to day operations are managed by team of professional Managers under the
leadership of Shri C.B. Patodia.
Allahabad Canning Limited is producing all types of Canned Fruits & Vegetables, Jams,
Jellies, Tomato products and Cereals. The Production is carried out under strict hygienic
condition & under the supervision of qualified food technologists.
The company is one of the largest suppliers to the Defence Forces having good presence
in the institutions like 5 star hotels, clubs etc. It also deals in exporting the products to
the Gulf countries. Allahabad Canning Ltd. is specialised to make customized products
for major clients who have placed orders in high volumes.
The industry with its vast range of products also has good presence in local market, in
spite of the fact that it never makes advertisements to popularise the brand image.
Major Clients Include:
 IRCTC
 Indian Army
 TAJ Group of Hotels
 amazon.in
 Walmart
 Big Bazar
 ITC Hotels
 Reliance Retail
 Big Basket
 Aditya Birla group
 The Leela Group of Hotels
 Le Meridien Hotel

8
BRIEF PROFILE: ALLAHABAD CANNING LTD.
Allahabad Canning Limited is a Public incorporated on 19 March 2015. It is classified
as Non-govt. Company and is registered at Registrar of Companies, Kanpur. Its
authorized share capital is ` 115,000,000 and its paid up capital is ` 109,845,880. The
company mainly involved in production, processing and preservation of meat, fish,
fruit vegetables, oils and fats.
Allahabad Canning Limited's Annual General Meeting (AGM) was last held on 21
September 2017 and as per records from Ministry of Corporate Affairs (MCA), its
balance sheet was last filed on 31 March 2017.
Directors of Allahabad Canning Limited are Chand Bihari Patodia, Brij Mohan
Agarwal, Chhedi Lal Agarwal and Dilip Patodia.
INFRASTRUCTURE: ALLAHABAD CANNING LTD.
The company is supported by a huge and advanced infrastructural facility that enables
us to cater various necessities and requirements of our patrons in a timely manner.
Disperses a large area, this infrastructural facility is precisely divided into several well
functional departments like admin department, Sales department, production
department, quality testing department, packaging department, etc. Well armed with
the modern processing machines and equipment, all these departments are handled by
their experienced team members.
Allahabad Canning Limited Details
 Corporate Identification Number (CIN):
U15122UP2015PLC069645
 Registration number: 69645
 FSSAI license no: 10012051000404
 Email address: birlasugar@birla-
sugar.com
 Registered address: P O HARGAON,
SITAPUR, UP 261121 INDIA

9
SPECIALITY: ALLAHABAD CANNING LTD.
With the vast distribution network and timely delivery, the industry is offering
optimum quality products with excellent packaging material at most reasonable rates.
Some of the unique factors that make us the foremost choice of clients are as follows:
 State-of-the-art infrastructure
 Experienced professionals
 Timely delivery
 Ethical business policies
 Transparent trade dealings
 Complete client satisfaction.

10
Birla Morton Product’s Description
S. No. Product Variants
1. Jam Pineapple
Mix Fruit
Apricot
Mango
Strawberry
2. Jelly Guava
3. Marmalade Orange
4. Chunk Pineapple
5. Juices Mango
Lemon
Orange
Pineapple
Lime Juice Cordial
6. Canned juices Pineapple
Apple
Mango
Guava
Mixed Fruit
Orange
Litchi
7. Canned eatables Pineapple: Slices
Chunks
Tid Bits
Cubes
Baby Corn
Mushrooms: Slice
Brine
Cherries (Whole)
Litchis (Whole)
Mango Slices: Totapari
Mango Pulp: Alphonso
Totapari
Mix
Peaches halved
Pears
Prime Garden Peas
Sweet Corn
Baby Corn
Tomato: Juice
Pulp
Paste
Puree
Jalapeno

11
Baby Gherkins (Pickled Cucumber)
Baked Beans
Baked Beans in Tomato Sauce
Corn Kernels
Sarson ka Saag
Fruit Cocktail
Fruit Fiesta
8. Crush Orange
Pineapple
Mango
Strawberry
9. Squash Orange
Pineapple
Mango
Lemon
10. Beverage
(Tinned)
Orange Beverage
Pineapple Beverage
Mango Juice
Tomato Juice
11. Bottled Red Chilli Sauce
Green Chilli Sauce
Tomato Ketchup
Mango Panna
Vinegar
Soya Sauce
Golgappa Pani masala
12. Slices Pineapple
Mango (Totapari)
13. Pickles Green Mango
Jackfruit
Mix Vegetable
14. Cereals Corn Flakes
Choco Flakes
Oats

12
Mango Products
Mangoes are an important part of the diets in certain parts of the world. The edible portion of
the fruit varies from 55 to 75 percent depending upon the variety. Most of the mangos can be
characterized as having a high sugar content (15-20%) and a low acid content (0.2-0.5%),
which would account for mangos' sweet, pleasant characteristics. Nutritionally, mangos are a
good source of vitamins A, C, and fiber. The variety of processed mango products is endless,
and variations exist from country to country and region to region. We can peel, slice, chop,
dice, and puree mangos, which we are able to preserve by dehydration, canning, bottling,
freezing, and pickling. We could recognize these mango products as dried fruits in trail
mixes, or as canned fruit slices in syrup, or as nectars, juices or blends in tropical fruit
punches, or as jams and jellies.
Mango is a unique fruit in terms of the diverse products processed from it, especially from its
immature to fully‐ripe stages. The most common processed mango products are puree/pulp,
nectar, juice, juice concentrate, and dried/dehydrated mangoes. Besides these common
products, there are a number of traditional products which are processed commercially in
major mango producing countries, such as pickles, sweet or sour chutney (a tomato ketchup
type sauce), amchoor or dried powder, mango leather, and a variety of soft drinks and
beverages (Siddiq et al. 2012). In addition, during the mango production season, freshly made
mango shakes and smoothies are popular in South Asian countries.
Mangoes are used for preparing a number of flavorful and nutritious products. Currently,
chemically preserved, canned, dried, and frozen forms of mango pulp and jams, jellies,
canned slices, dehydrated pulp (mango leather), frozen chunks and slices, traditional pickles,
and chutneys, are commonly processed from mangoes (Occena‐Po 2006).
TABLE I

13
Mango Slices:
Raw Material
(Mangoes)
Grading
High Quality Medium Quality Average Quality
(Large Size No Blemishes)(No Blemishes Normal Size)(Normal Size with blemishes)
Placing into crates (10 Kg avg. wt.)
Cleaning (with tap water)
Peeling (Through hand peelers)
Cutting into slices and seed separation
Grading (On the basis of Size)
Washing in CaCO3 water solution (Conc. 1kg in 180 ltr of water)
Final Inspection
For 850 g Product: 540g Mango Slice, 300g Sugar Syrup
Seaming of Cans
Exhausting (at 180-190 °F)
Cleaning of Cans (To avoid any spillage of product on outer surface)
Retorting
(at 210 °F, 12 lb for 30 min)
Cooling in Cistern full of water
(for 30 min approx.)
Labelling
Storage
(Food Grade Store)
Product ready & Filling

14
Mango Pulp:
Fully matured Overripe Fruit
Peeling
Seed Separation
Pulping
Straining through sieve (1/2”, 1/8”, 1/32”)
Heating
(Sugar is also added except for natural pulp)
Filtration (Sieve Size 1/64”)
Pulp is added to Mixing Tank
Boiling 180 °F for 15-30 min
Final TSS Measurement- 13 °B
Acidity- 0.5%
Filling hot into Cans
Exhausting
(180-190 °F for 5 min)
Seaming
Cleaning of Cans in Water
Retorting
(210 °F for 40 min)
Cooling in Cistern full of water (for 30 min approx.)
Labelling
Storage (Food Grade Store)
Product ready

16
Litchi Products
Litchi is the most important sub-tropical evergreen tree and most renowned edible fruits of
soapberry family, Sapindaceae. It is botanically designated as Litchi chinensis Sonn.
(Nephelium litchi cambess) and is widely known as litchi and regionally as lichi, lichee,
laichi, leech or lychee. It is known as queen of the fruit due to its attractive deep pink/red
colours, deliciously flavoured sweet and juicy aril. It has high nutritive value and suitable for
geotropic weak person. Litchi appears to be native of Southern province of China, where it
flourishes especially along rivers and near the seacoast. It has a long and illustrious history
having been praised and pictured in Chinese literature from the earliest known record in 1059
A.D. The cultivation of litchi is spread over the years through neighbouring areas of
southeastern Asia and offshore islands. Litchi reached Eastern India (Tripura) first via Burma
(Now Myanmar) by the end of 17th Century and thereafter by the end of 18th Century it was
introduced to Bengal. Litchi is now an important commercial fruit crop in India due to its
high demand in the season and export potentiality. Cultivation of litchi is widely spread in
eastern India covering approx 100 kms width from foot hills of Himalaya from Bengal to
Punjab, which provides livelihood opportunities to millions of people in the region. In India
bulk of litchi growing areas lies in Bihar, other areas are sub-mountain tracts of Uttar
Pradesh, West Bengal, Punjab, Assam, Tripura and Odisha.
TABLE II

17
Litchi Whole:
Fully Ripe Matured Litchi Fruit
Primary Washing
Pruning (Removal of Stem)
Sorting
(On the basis of Size)
Peeling
De-stoning (Removal of Seed)
Secondary Washing
Inspection of Foreign particles
Final Washing
Weighing and balancing
Sugar Syrup addition (TSS 24 °B)
(Sugar Crystal 100 Kg, Water 40 Kg)
Exhausting
(at 176 °F for 5-7 min)
Seaming
Washing of Can
Retorting
(at 210 °F for 30 min)
Labelling
Product ready & Filling into Cans
into Can

19
Tomato Products
Tomato in India occupies second position amongst the vegetable crops in terms of
production. Another encouraging trend has been that India's production level of processed
tomato has risen by 50 per cent. The main objective of processing is to supply wholesome,
safe, nutritious and acceptable food to consumers throughout the year. Tomatoes and tomato-
based foods are considered healthy for the reason that they are low in calories, but possess a
remarkable combination of antioxidant micronutrients.
India ranks first in the world in production of fruits and second in vegetables, accounting
roughly 10 and 15 per cent, respectively, of total global production. India have a strong and
dynamic food processing sector playing a vital role in diversifying the agricultural sector,
improving value addition opportunities and creating surplus food for agro-food products.
Presently, a mere 16.7 per cent of fruits and vegetables are processed, even as the country
ranks second in the world in terms of production. This is comparatively low when compared
to other countries like Brazil (30 per cent), USA (70 per cent) and Malaysia (82 per cent).The
National policy aims to increase the percentage of food being processed in the country 25 per
cent by 2025.
TABLE III

20
Tomato Paste: (1 Lot=180 Kg.)
Water is heated in Steam Jacketed Kettle
(25-30 ltr)
Boiling of water
Addition of Pre-manufactured Tomato Paste
(75 Kg.)
Addition of Sugar
(5 Kg)
Sodium Benzoate is added (25 g)
Heating in Steam Jacketed Kettle
(at 200 °F)
Final TSS Measurement
(25 °B)
Exhausting
(at 180 °F for 5-7 min)
Seaming
Cleaning of Cans in Water
(To avoid any spillage of product on outer surface)
Retorting
(210 °F for 40 min)
Cooling in well of normal water
Labelling
Storage
(Food Grade Store)
Product ready for filling into Cans

21
Tomato Puree: (1 Lot=180 Kg.)
Boiling water in Steam Jacketed Kettle
Pre manufactured Tomato Paste is added
(75 Kg)
Addition of Sugar
(5 Kg.)
Preservative (Sodium Benzoate) is added
(25 g)
Transferring the content into Mixing Tank
Pasteurisation
(Heating at 200 °F)
TSS Measurement- 10 °B
Filling into Cans
Exhausting
(at 180-190 °F for 5 min)
Seaming
Cleaning of Cans
Retorting
(at 200 °F for 75 min)
Cooling in cistern full of water
(for 30 min)
Labelling
Storage
(Food Grade Store)
Product ready

22
Tomato Ketchup: (1 Lot=180 Kg.)
Premanufactured Tomato Paste 108 Kg
Water is added
Sugar Syrup is added
Preparation recipe:
Sugar- 84 Kg
Water- 20 ltr
Sodium Benzoate solution (40g mixed well in water)
Spice Mix is added
Composition: Onion 2 Kg
Ginger 250 g
Garlic 250 g
Garam Masala 30 g
Mustard Powder 30 g
Coriander Powder 60 g
Black Pepper 75 g
Red Chilli Powder 120 g
Salt is added
Thickening agent
(Xanthan Gum is added)
Straining
(through 1/64” sieve)
Heating
Acetic Acid is added
Filling into Bottles
Retorting
Cooling for 30 min in cistern full of water
Labelling
Storage
(Food Grade Store)
Product Ready

23
Baked Beans in Tomato Sauce: (Lot=360 Kg.)
Tomato Sauce Preparation:
Tomato Paste mixed with water- 180 Kg
Spices Mix- 2.7 Kg
(Onion 2 Kg, Garlic 250g, Ginger 250g, 100g Red Chilli Powder,
Garam Masala 50g, Black Pepper 30g, Clove Oil 20ml )
Sugar Syrup- 18 Kg & Salt- 3 Kg
Citric Acid monohydrate- 100 g & Acetic acid-150 ml
Heating in Steam Jacketed Kettle
TSS Measurement (17.5-18 °B)
Holding till it reaches room temperature
Ready for addition with beans
Baked Beans:
Raw Matured Beans- 100 Kg
Soaking for overnight (approx. 10 hours)
Primary and Secondary Washing
Blanching at 200 °F for 25 min
Filled into Cans
Prepared Tomato Sauce is added
Exhausting
Seaming Leaving head space of 0.6-1.6 cm
Cleaning through water
Retorting
(242 °F for 85 min at 12 Lb pressure)
Cooling in well of normal water
Storage
(Food Grade Store)
Product Ready for Filling

25
Cherry Fruit
Cherry belongs to the genus Prunus of the Rosaceae, or rose family. The genus Prunus
includes other stone fruits such as almond, apricot, plum, peach, and nectarine. There are
many cherry species, but only a few have been domesticated. The sweet cherry (Prunus
avium) trees are large (30 feet to 40 feet tall) and usually pyramid shaped. Branches grow
upright. The fruits are large, have a deep stem cavity, vary in colour from light yellow to dark
red to purplish black, and the stems or pedicels are about 1.5 inches long. Flowers arise from
clusters of 2 to 5 flowers on short spurs with multiple buds at tips; the distal bud develops
into a leafy shoot. The flesh ranges in texture from tender to firm, and is sweet. Most sweet
cherries are consumed as fresh fruit. The tart cherry (Prunus cerasus), is sometime called
"red cherry" or "sour cherry" and may have arisen from an unreduced pollen grain of Prunus
avium crossed with Prunus fruiticosa. Trees are very cold hardy, but are shorter lived than
sweet cherry. The fruit is relatively small, and have a higher acid and lower sugar content
than sweet cherry. Tart cherries are used for processing, jam, and pie filling. The Duke cherry
is a hybrid of Prunus avium and Prunus cerasus and all gradations between the two species
exist, but most varieties more closely resemble sweet cherry.
Anthocyanin pigments are responsible for the red or purple colours in cherries. Anthocyanins
are one class of flavonoid compounds that are dietary phenolics and they have antioxidant
properties. Cherries are also a source of a number of vitamins and minerals
TABLE IV
Health benefits of cherry fruit
 Cherries are one of the very low calorie fruits; yet are rich source of nutrients,
vitamins, and minerals.
 Consumption of cherries has potential health effects against chronic painful episodes
such as gout arthritis etc.
 Cherry fruits are very rich in stable anti-oxidant melatonin.
 The fruits, especially tart cherries are exceptionally rich in many health promoting
flavonoid poly phenolic anti-oxidants such as lutein, zeaxanthin and beta carotene.

26
Cherry (Whole) Processing:
Matured Red Cherries from Kashmir
Pruning (Removal of Stem)
Grading ̶ On the basis of:
Size: 0.6”,
0.65”,
1.2”
Degree of Maturity:Fully riped
Over riped,
Under riped
Primary and Secondary Washing
Sugar Syrup (Sugar- 40 Kg, Water- 20 Kg)
Erythrosine Red- III Colour Addition- 20 g
Final Inspection
Weighing & Balancing
(Cherries 450±10g, Can wt. 110g, Sugar Syrup- 290 g)
Exhausting
(at 180-190 °F for 5 min)
Seaming
Cleaning of Cans
Retorting
(210 °F for 20 min)
Labelling
Storage
Food Grade (F.G.) Store
Ready product filled into Can

28
Chilli Sauce
With the fast changing scenario in food consumption pattern, the younger generation has
developed a liking for more and more fast foods and tomato sauce and chilli sauce are
important accompaniments. Chilli sauce is used in garnishing many dishes.
Use
Chilli sauce can be used for many recipes due to its pungent, sweetish and sour taste. Chilli
sauce can be used in snack foods like Gobi Manchurian, noodles and as an adjunct for
Samosa, Cutlet, Bread etc.
FSSAI Specification for Chilli Sauce
Percent acidity (expressed as acetic acid) : Not less than 1%
Total soluble solids (w/w) (salt free basis) : Not less than 8.0%
Green Chilli Sauce Processing: (1 Lot= 180 Kg)
Premanufactured Green Chilli Paste
Addition of Water
Straining
Heating of paste till boiling
Transferring of paste in Mixing Tank
Blanched peeled Potato is added along with Onion, Ginger and Garlic Paste
Addition of sugar, pectin & spice mix
(headless clove, cardamom, cumin, cinnamon & mace)
Heating
TSS Measurement 14 °B.
Addition of salt & mixing
Heating stopped
Addition of Acetic Acid & Sodium benzoate
Final mixing & TSS Measurement 25 °B
Labelling
Product Ready & Filling into bottles
& Closing

29
Red Chilli Sauce: (1 Lot= 180 Kg)
Premanufactured Red Chilli Paste
Addition of Water
(Boiled)
Straining
Transfer into Steam Jacketed Kettle
Paste is heated till boiling
Transfer of Paste into Mixing Tank
Blanched peeled Potato is added along with Onion, Ginger and Garlic Paste
Addition of sugar, pectin & spice mix
(clove, cardamom, cumin, cinnamon & mace)
Pasteurisation
(Continuous heating below 200 °F)
TSS Measurement- 20° B.
Addition of salt & mixing
Heating stopped
Addition of: Acidity Regulator- Acetic Acid
Preservative- Sodium benzoate
Mixing of added ingredients
Straining (through 1/32” Sieve)
Filling into bottles & Capping
Labelling
Storage
(Food Grade Store)
Product ready

30
Soya Sauce: (1 Lot= 180 Kg)
Pre-manufactured Soya Sauce Making extract
Composition: Soya Beans- 0.7 Kg
Wheat- 70 g
Water- 40 Kg
Blanching
(for 50 min)
Leaving for fermentation
(4 days approx.)
Straining through Muslin Cloth
Sugar Syrup addition:
Sugar Crystal- 45 Kg
Salt is added- 9 Kg
Addition of: Colouring Agent: Natural Caramel Colour- 6.5 Kg
Acidity regulator: Acetic Acid- 750 ml
Spice Mix- 10 Kg is added
(Ginger, Garlic, Cumin, Black Pepper, Red Chilli, Coriander)
Pasteurisation
(Continuous heating at temperature lower than 200 °F)
Acidity-1.2 %
Filling hot into Plastic bottles
Lidding
Cooling in natural air flow
Labelling
Storage
(Food Grade Store)
Product Ready

32
Jam, Jelly & Marmalade
Historically, jams and jellies may have originated as an early effort to preserve fruit for
consumption in the off-season. As sugar for their manufacture became more affordable, the
popularity and availability of these fruit products increased (Anon., 1983). Jellies, jams,
preserves, and marmalades are primarily distinguished by the form in which their fruit
component is incorporated. In jellies, only strained fruit juice is used, while jams are made
with crushed or ground fruit material. Preserves are made with whole fruit (if sufficiently
small) or large pieces of fruit (Ahmed, 1981). Marmalades are basically clear jellies in which
slices or shreds of usually citrus peel are suspended. Regardless of their form, all are sugar–
acid–pectin gels or low-methoxyl pectin–calcium gels. Their structure, appearance, and
mouthfeel result from a complex interaction between pectin level and functionality, pH, sugar
type and content, setting temperature, and, in the case of low-methoxyl pectin gels, calcium
content.
Originally, jam or jelly production relied on the native pectins of incorporated fruit for gel
formation. Fruit was cooked with sugar, extracted acids, and pectins, and if the proper
balance of sugar level, pH, and pectin content were achieved, a satisfactory jelly was
obtained; however, modern manufacturing requirements for uniform gel strength and
appearance preclude reliance on fruit component pectins, which may vary in content and
quality, depending on fruit maturity and variety. In spite of the current availability of other
gelling agents, pectin remains the universal choice for jams and jellies, in part because of its
presence as a natural fruit ingredient and also because of the characteristic consistency that
pectin imparts to a gel. Pectins of known quality and gelling capacity (usually derived from
citrus or apple by-products) are added to jelly and jam formulations to achieve desired gel
strength. It is estimated that 80 to 90% of commercial pectin production, which totals 6 to 7
million kg, is used in the production of jellies and jams (Crandall and Wicker, 1986)
Jam :
It is a product prepared by boiling the fruit pulp (sometimes whole fruit) with sufficient
quantity of sugar to a moderately thick consistency, firm enough to hold the fruit tissues in
position. Apple, Pear. Raspberry, Apricot, Mango, Strawberry and some other fruits are used
for preparation of jams. It can be prepared from single kind of fruit or from two or more
varieties. Commercial jams such as tutti-frutti can be prepared from pieces of fruit, fruit
scraping and pulp adhering to cores of fruits which are available in plenty of canning
factories.
Jams are commercially produced by using 45 parts of fruits pulp for every 55 parts of sugar.
It contains 0.5-0.6% acid and invert sugar should not be more than 40 % It should contain
68% soluble solids as determined by refractometer when cold and uncorrected for insoluble
solids.
Jelly:
It is a product prepared by boiling clear fruit extract (with or without) water with sugar and
boiling the mixture to a stage at which it will set to a clear get.
Marmalade:
Marmalade is a fruit jelly in which the slices of the fruit or the peel are suspended. The term
generally is associated with the products made from citrus fruits like oranges and lemons, in
which shredded peel is included as suspended material.

33
Apricot Jam: (1 Lot= 180 Kg)
Peach Pulp
Straining
Heating of strained pulp
(De-sulphitation- dissolved KMS is removed upto 32 ppm)
Sugar Syrup (TSS 76 °B)
Preparation Recipe:
Sugar 100 Kg
Water 20-24 Kg
Pulp is transferred into Mixing Tank
Pasteurisation
(Heating of Mix)
Prepared Sugar Syrup is added
Addition of: Thickening agent (Pectin)
Acidity Regulator (Citric Acid)
Colouring agent (Propylene Glycol Caramel Color)
Flavour (Apricot Fruit)
TSS Measurement 70 °B
Filling into Glass Jar
Capping
Labelling
Storage
(Food Grade Store)
Product ready

34
Mix Fruit Jam: (1 Lot= 180 Kg)
Raw Fruit Pulp
(Mango, Pineapple, Litchi, Orange, Guava, Cherry, Pears)
Straining
Heating of Pulp (Desulphitation- Removal of KMS)
Sugar Syrup Preparation:
Sugar 100 Kg
Water 20-24 Kg
Removal of Scum (Filtration)
Heated pulp is pumped into Mixing Tank
Addition of: Prepared Sugar Syrup
Citric Acid
Colour: Ponceau 4R, Frooti IV & Carmozine
Essence: Raspberry, Apricot, Strawberry
Pectin is added when TSS reaches 78 °B
Further heating
TSS Measurement- Final TSS 70 °B
Filling into glass jar
Lidding
Cleaning of Jar
(To avoid any spillage on outer surface)
Labelling
Storage
(Food Grade Store)
Product ready

35
Pineapple Jam: (1 Lot= 180 Kg)
Pineapple Juice (30 Ltr)
Straining
Heating of Pulp
(Desulphitation- Removal of KMS)
Sugar Syrup Preparation
Removal of dirt, if any (using muslin cloth)
Heated pulp is pumped into Mixing Tank
Pasteurisation
(Heating of Mix below 200 °F)
Addition of: Prepared Sugar Syrup
Citric Acid
Colour:
Essence: Pineapple
Pectin is added when TSS reaches 74-76 °B
Further heating
TSS Measurement- Final TSS 70 °B
Filling into glass jar
Lidding
Cleaning of Jar
Labelling
Storage
(Food Grade Store)
Product ready

36
Strawberry Jam: (1 Lot= 180 Kg)
Preserved Strawberry Pulp
Straining
Transfer of mix into Kettle
Addition of Sugar Syrup
Acidity regulator
(Acetic Acid) is added
Thickening agent
(Pectin) is added
Flavouring agent
(Strawberry Flavour) is added
Colouring agent
(Acrayl colour) is added
Preservative is added
(Sodium Benzoate)
Pasteurisation
(Heating of Mix)
Final TSS Measurement 68-70 °B
Filling into clean and dried glass jar
Jars are cool down in running water
(To avoid any spillage on the outside of jar)
Left for settle down in natural air flow
Labelling
Storage
(Food Grade Store)
Product ready

37
Guava Jelly: (Lot= 50 Kg.)
KMS Preserved Guava Juice extract
(25 Kg.)
Straining
Heating at high temperature with stirring
(Desulphitation- Removing dissolved KMS from strained mix)
Sugar Syrup Addition:
Sugar 36 Kg.
Pasteurisation in Steam Jacketed Kettle
(continuous heating at temperature below 200 °F)
Addition of Thickening agent:
Pectin- 250 g mixed well in water
Slow heating
Acidity regulator: Citric Acid- 250 g is added
Preservative: Sodium Benzoate- 0.5 g is added
Acidity- 0.5 to 0.7%
Filling (hot) into glass jars
Cleaning of Jars in water
Labelling
Storage
(Food Grade Store)
Product ready

38
Orange Marmalade: (1 Lot= 180 Kg.)
Fully Riped Orange
Washing
Peeling outer yellow portion thinly
Cutting yellow portion into fine shreds
Boiling
Straining of extract
Addition of Sugar Syrup- 50 ltr (TSS- 80 °B)
Cooking
Addition of prepared shreds (9 Kg) and Orange Juice (24 ltr)
Acidity Regulator: Citric Acid- 800 g
Thickening agent: Pectin 800 g
Further boiling
Test for final consistency
Cooling
Colouring agent- Sunset Yellow (65 ml) & Flavouring agent- Orange Oil (120 ml)
Filling in glass jars
Sealing
Labelling
Storage
(Food Grade Store)
Product ready

40
Pickle
Pickles are usually made from a mixture of vegetables and fruit. They are eaten as a savoury,
spicy accompaniment to a meal. Pickles are preserved by a combination of increased acidity
(reduced pH), added salt, reduced moisture and added spices. Pickles can be prepared using
one of two main methods: lactic acid fermentation of vegetables, either with or without the
addition of salt the preservation of vegetables in acetic acid (vinegar). The products made by
these two methods are very different -each one has its own distinctive taste and texture.
Following pickle variants are manufactured at Allahabad Canning Ltd.:
 Raw Mango Pickle
 Red Chilli Pickle
 Mix Vegetable Pickle
 Jackfruit Pickle
TABLE V
Example of different types of pickles
Source: Food Processing Technology Fellows P.
Raw Mango Pickle:
Fully matured fresh raw mangoes
(10 Kg)
Washing (In tap water)
Cutting into uniform sizes
Brine Solution (2-3%) is added
(4 Kg Salt in Water)
Cleaned dried powder of spices is added
(red chillies- 0.3 Kg, turmeric-100 Kg and mustard-0.2 Kg)
Edible Oil is added and frying of prepared mix along with
seasoning like kalonji/fenugreek-0.2 Kg
Garlic and Ginger paste, Vinegar is added
Curing for a week in container
Filling into Jars
Product Ready for consumption

41
Drinks
A wide range of drinks can be made using extracted fruit juice or fruit pulp as the base
material. Many are drunk as a pure juice without the addition of any other ingredients, but
some are diluted with sugar syrup. The types of drink made from fruit can be separated into
two basic types;
- those that are drunk straight after opening
- those that are used little by little from bottles which are stored between use.
The former groups should not require any preservative if they are processed and packaged
properly. However, the latter group must contain a certain amount of permitted preservatives
to have a long shelf-life after opening.
TABLE VI
Quality control in Fruit Drink Processing
The freshness and quality of the expressed fruit juice is central to the quality of the final
product. As soon as the juice is expressed from the fruit it starts to deteriorate, both as a result
of chemical activity (enzyme action) and bacterial spoilage. It is important to move from the
juice extraction stage to pasteurisation as quickly as possible to minimise any spoilage.
Extracted fruit juice that is left to stand for long periods in the heat will start to ferment and
may start to discolour due to enzyme activity. The juice should be stored in a refrigerator (if
one is available) or in a cool place and away from the direct sunlight. It should be collected
into a clean, sterile container (food grade plastic buckets is the best option) and covered to
keep out dirt, dust and insects. For the best quality product, it is essential to work quickly
between the extraction of the juice and the bottling stage. The longer the juice is out of the
bottles, the more chance there is of contamination.
TABLE VII
Chemical preservatives that are generally added to fruit juices

42
Mango Drink: (1 Lot= 180 Kg.)
Sliced Mango Fruit
Variants: Dussheri- 30 Kg.
Totapuri- 20 Kg
Bengalpalli- 10 Kg.
Pulping
Straining (through 1/64” sieve)
Transferring of strained mix into Steam Jacketed Kettle
Sugar Syrup Addition:
Pasteurisation
(continuous heating below 200 °F)
Addition of Citric acid monohydrate- 220 g
TSS Measurement-15 °B
Acidity-0.3 %
Product ready
Filling (hot) into labelled Cans
Seaming
Cleaning of Cans
Retorting
(210 °F for 35 min)
Storage
(F. G. Store)

43
Litchi Drink: (1 Lot= 180 Kg.)
Crushed, Over-riped, peeled Litchi Fruit
Pulping
Filtration
(through 1/64” Sieve)
Transfer of filtered pulp into Mixing Tank
Water is added
Heating of mix
(till boiling temperature is achieved)
Filtration through Muslin Cloth
Filling into labelled Cans
Seaming
Retorting
(270 °F for 30 min)
Storage
(Food Grade Store)
Product ready

44
Pineapple Drink: (Lot= 360 Kg.)
Pineapple Juice (120 ltr)
Filtration through muslin cloth
Transfer of product into Steam Jacketed Kettle
Water is added
Heating of Mix (Pasteurisation)
Addition of: Sugar Syrup (Sugar –22 Kg.)
Pineapple Flavour – 70 ml
Citric Acid – 540 g
Slow heating
Final TSS Measurement– 14 °B
Acidity– 0.35%
Again, Filtration through muslin cloth
Filling (hot) into Labelled Cans
Seaming
Retorting (210 °F for 35 min)
Product Ready

45
Mix Fruit Drink: (1 Lot= 180 Kg.)
Fruit pulp Mix
Composition: Pineapple Juice- 30 Ltr
Guava Pulp- 12 ltr
Mango Pulp- 18 ltr
Orange Juice-6.5 ltr
Straining through 1/32” and 1/64” sieve
Transfer of product into Mixing Tank
Heating of mix
Sugar addition
Sugar Crystal- 23 Kg.
Preservative (Ascorbic Acid) is added- 80 g
Acidity regulator (Citric Acid) is added- 140 g
Filling into labelled Cans
Seaming
Retorting (210 °F for 35 min)
Product ready

46
Mango Panna: (1 Lot=75 Kg)
Strained Mango Pulp
(45 Kg.)
Sugar Syrup Preparation: Crystal Sugar – 80 Kg.
Addition of:
Mint (Pudina)-3 Kg
Black Salt-3.3 Kg
Table Salt- As required
Cumin Powder- 700 g
Black Pepper-250 g
Ginger- 250 g
Lemon Juice-0.2 Kg
Citric Acid/Malic Acid-2.2 g
Pasteurisation (Continuous heating below 200 °F)
Mixing of Ingredients well
Colouring agent- Tartazine Brillant Blue is added- 15 g
Preservative is added: Sodium Benzoate- 5g
Sodium Metabisulphite NaMS-90g
Emulsifier- Xanthan Gum is added (200 g)
Salt-5%
Acidity-1.60%
SO2 – 32 ppm
Straining (through 1/32” sieve)
Filling into Plastic Bottles
Labelling
Storage
(Food Grade Store)
Product Ready

47
Lime Juice Cordial: (Lot= 200 Kg.)
Lemon Juice (filtered) - 50 Kg.
Sugar Crystals- 65 Kg.
Water- 80 Kg
Citric acid
(as required to obtain desired acidity)
Addition of Flavouring agent: Lemon Flavour- 425 ml
Lime Juice mixed soda water- 425 ml
Colouring agent is added
Preservative: Sodium Benzoate- 15 gm
Testing of SO2 Conc.
(less than 320 ppm)
Acidity-1.65%
Filling into Plastic bottles
Labelling
Storage
(Food Grade Store)
Product Ready

48
Crush and Squash
Crush is a fruit squash or fruit beverage that contains at least 25% fruit juice or pulp and
55% TSS. It also contains 1.0 % acid, and is diluted before use, such as pineapple crush.
Squash is a type of fruit beverage containing 25–33 % fruit juice or pulp, 40–50 % total
soluble solids (TSS), 1.0 % acid, and 350 ppm sulfur dioxide. This beverage is diluted with
chilled water before serving (Jood and Khetarpaul 2002); for example, orange squash, lemon
squash, mango squash, pineapple squash.
Orange Crush: (Lot= 480 Kg.)
Orange Pulp- 120 Kg
Water-120 Kg
Addition of Syrup in Pulp Mix
Pasteurisation
(Continuous heating at temperature below 200 F)
Addition of
Flavouring agent: Sweet Orange Flavour- 900 ml
Orange Oil is added- 1500 ml
Acidity- 1.2 to 1.25 %
Sulphur Dioxide SO2- 350 ppm
Filling hot into Plastic Bottles
Weighing and Capping
Labelling
Storage
(FG Store)
Product ready

49
Lemon Squash:
Preserved Lemon Juice extract - 60 Kg.
Straining through 1/32” sieve
Sugar - 65 Kg.
Water -80 Kg.
Pasteurisation
(Continuous heating at temperature below 200 °F)
Acidity regulator: Citric acid in required amount is added
Flavouring Agent- Lemon Flavour- 800 ml is added
Preservative: Sodium Benzoate-25 g is added
Slow Heating
Acidity- 1.50 %
SO2- 350 ppm
Filling into plastic bottles
Cleaning of bottles
(To avoid any spillage outside)
Labelling
Storage
Product ready

51
INTERNAL LABORATORY TESTING AT QUALITY ASSURANCE LAB
ALLAHABAD CANNNG LTD.
Laboratory testing is an important process, which relies on scientific analysis to identify problems
with food products. It provides analytical data on the quality of a product or production process to
support quality control in the HACCP system. The objective of quality control is to identify
contaminants in raw material, or contamination after a product is produced and before it is placed
on the market. Additionally, laboratory testing is important for the research and development of
new products, including, for example, the choice of ingredients or components, the design of food
processing, shelf-life studies and sensory evaluation of products. This is the kind of information
food scientists need when developing new products. Another benefit of laboratory testing is
compliance with regulations for both the import and export of food products to different countries.
As we know, Food regulation is designed to protect public health and the safety of consumers.
Therefore, to ensure high quality product specification, following tests are performed before
storing the product and market dispatch:
1. Internal and external condition of the can:
Examine the internal surface for any corrosion, pitting, scratching, defects in lacquering,
leakages, discolouration, puffing etc.
2. Pressure Test of Cans
3. Determination of soluble solids:
Principle: Measurement of the refractive index of the test solution at 20°C, using a
handheld refractometer. It provides direct reading of the total soluble solids content when
well-mixed sample is placed on the refractometer scale.
4. Determination of pH value:
Principle: pH is the measurement of H+
ion activity; It measures active acidity. pH may be
determined by measuring the electrode potential between glass and reference electrodes;
The Can Pressure Gauge apparatus is used to measure
the vacuum pressure of seamed cans. The gauge is
placed on top of the can and the piercing needle
is forced through the top of the can.
The rubber collar forms a temporary seal to allow for
measurement. The instrument is designed for using
near the product line, Consists of a 0 to 76cm Hg
vacuum gauge, pierce point, and rubber collar.
It is also available with dual scale to measure pressure
to 15 psi.
Technical data:
Vacuum range: 0-0.1 MPa; (0-15 Psi; 0-76 cm Hg)
Resolution: 0.005 MPa

52
pH meter is standardised using standard pH buffers. Use homogenized sample for the
determination of pH.
Procedure: Immerse the standardized electrode tip into the solution and stir the sample
gently by means of a rod or "flea" to give a constant pH value on digital scale.
5. Drained Weight Measurement
Principle: The sample is drained on a standard mesh sieve. The weight of the material
remaining on the sieve is expressed as percentage of the can contents.
Apparatus: Sieve with square openings, 2.5 mm x 2.5 mm (No. 6 B.S.). Use a sieve of 20
cm if the total weight of contents is less than 1.5 kg and of 30 cms if the weight is more
than 1.5 kg.
Procedure: Weigh the full can. Open and pour the entire contents on a circular sieve.
Without shifting the product, incline the sieve to facilitate drainage. In the case of products
with a cavity such as peach halves, invert if necessary, so that the liquid can drain through
the cavity but otherwise the product should not be disturbed. Drain for two minutes.
Weigh the drained solids and the empty can.
6. Test for Consistency using Bostwik Consistometer
The Consistometer is a low cost,
durable, instrument for accurately
checking laboratory or production
samples against consistency, viscosity
or flow rate standards.
Procedure: A measured sample up to
100 ml, is placed in the reservoir
behind the gate of the consistometer.
The gate is released, by pressing the
lock release lever - the spring action
ensures it open instantaneously. As the
fluid flows down the instrument its
progress can be accurately measured
using the graduated scale.
By comparing the flow rate to
specified time periods the physical
properties of the sample can be
calculated.
% drained weight =
𝑫𝒓𝒂𝒊𝒏𝒆𝒅 𝑾𝒆𝒊𝒈𝒉𝒕
𝑵𝒆𝒕 𝑾𝒆𝒊𝒈𝒉𝒕 𝒐𝒇 𝑪𝒐𝒏𝒕𝒆𝒏𝒕𝒔
× 𝟏𝟎𝟎
Net wt. of contents = Gross weight – tare weight of the can

53
7. Determination of Acidity
Titrable acidity can be expressed conveniently in gm acid per 100 gm or per 100 mL as
appropriate, by using the factor appropriate to the acid as 10 mL of 0.1 N NaOH equals to
Citric acid anhydrous – 0.64 gm
Take 2 gm well food sample, dilute to 10 mL with distilled water. Titrate with 0.1 N
NaOH using 2 drops phenolphthalein. Titrate it till it reaches pink end point persisting for
30 seconds. Determine acidity as % of 0.1 N NaOH per taken amount of sample by
following equation.
8. Determination of Sulphur dioxide (SO2) by Ripper Method
Apparatus:
a) Conical flasks
b) Beakers & pipette
Reagents:
a) Sodium bicarbonate
b) Conc. HCl
c) Starch
d) Iodine Solution
Procedure:
a) Pipette 10 ml of sample into a 250 ml conical flask.
b) Dilute it using 25 ml distilled water.
c) Add to it powdered Sodium Carbonate and starch each weighs 5 g.
d) Add 5 ml of Conc. HCl into the conical flask.
a) Shake the flask to ensure thorough mixing then leave the solution for some
time.
e) Now, Titrate the mix with
𝑁
10
solution of Iodine untill deep blue colour
persists.
f) Record the reading and calculate the SO2 as given by the formula:
% Acidity =
𝑻𝒊𝒕𝒓𝒆 𝑽𝒂𝒍𝒖𝒆×𝑨𝒄𝒊𝒅𝒊𝒕𝒚 𝒇𝒂𝒄𝒕𝒐𝒓 𝒇𝒐𝒓 𝑨𝒏𝒉𝒚𝒅. 𝑪𝒊𝒕𝒓𝒊𝒄 𝑨𝒄𝒊𝒅
𝑨𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆 𝒕𝒂𝒌𝒆𝒏
µg/gm (ppm) of sulphur dioxide =
𝟑.𝟐× 𝑻𝒊𝒕𝒓𝒆 𝑽𝒂𝒍𝒖𝒆
𝑺𝒂𝒎𝒑𝒍𝒆 𝑾𝒆𝒊𝒈𝒉𝒕
× 𝟏𝟎𝟎𝟎

54
Sample document of Lab testing at Allahabad Canning Ltd.
CONFIDENTIAL

55
EQUIPMENTS AT ALLAHABAD CANNING LTD.
Induction Cap Sealer:
Induction sealing is a non-contact process, which is used to bond a foil disk or to seal the
opening of a container. The technique provides the user with a tamper evident seal. The seal
assures product integrity and prevent any chances of leakage. It increase the products shelf
life, reduce pilferage, and ensures maximum customer satisfaction.
The method can also be used for different types of containers and also used for foods, drugs,
chemicals and petroleum products.
Peeler Machine:
 Peeler machine is very suitable for all types
of food processing industries.
 Double coated abrasive silicon carbide gives
us maintenance free long life.
 Uniquely in built water flow system is very
helpful for saving of time, energy, cost and provides
us best performance.
 Comfortable operating design needed low
maintenance and easy to clean.
Mechanical Induction Cap Sealer
Industrial Peeler

56
Laser Marking Machine:
Laser Marking Machine is designed for bar codes marking, 2D codes and characters, graphics
and other information on any kinds of metal lid. Integrated with high-performance CO2/ Fiber
laser source, import high-pixel CCD camera and micron-level mobile module, PCB Laser
Marking Series is competent to pre-marking automatic positioning.
Features:
 High-performance CO2 / Fiber laser has high-quality laser beam, small focusing spots
and well-distributed power.
 The high-pixel CCD camera makes automatic positioning, identification and feedback
reporting come true.
 Gantry structure and synchronous transmission guideways ensure the stable and
precision performance.
 The function of automatic focusing and track width adjusting are designed to match
up different production line.
Industrial Laser Marking Machine

57
Blister Packaging Machine:
Blister packaging machines are electromechanical equipment, consisting of stationary and
moving parts which help to seal products in preformed cavities. Through various mechanical
movements, a blister packaging machine forms cavities on formable web material, fills the
cavities and covers them with an appropriate material.
Mechanism: Blister Packaging Machine
 Switch on the Blister Packing Machine (Unwinding Stations Start Moving)
First, switching on the machine will set the unwinding stations in motion. I hope you can
locate the unwinding stations of the blister packaging equipment:
Parts of blister packing
equipment

58
Here, we have:
 Station 1: It supplies the forming material, i.e. one which will form the base of the
blister back.
 Station 2: Supplies the lidding material, i.e. on that covers the content of the cavity.
Normally, the two stations supply material at a corresponding speed. Again, the positions of
the two stations will depend on a design the blister packaging machine manufacturers will opt
for. At this point, the forming film will then move to the first stage of processing:
 Heating Station (Temperature will Depend on the Type of Material)
So, this blister packaging machine mechanism is for thermoforming blister packaging
machines. During the preheating stage, the blister packaging equipment heats the form film
until it becomes pliable (easy to form). It uses both the lower and upper plates for a uniform
and consistent heating. We need set the heater temperature depending on the type of material.
For instance, you can set the machine to:
 120 to 140°C in case the forming film material in polyvinyl chloride (PVC)
 140 to 150°C for a polypropylene (PP) as a forming film
After reaching the correct temperature, it will then move to the next stage.
Heating section

59
 Forming Cavities/Pockets on the Film
In thermoforming, the blister packing machine manufacturers use either die plates or
compressed air to form suitable cavities. Once we have these cavities, the machine will then
cool the film to form a rigid plastic cavity.
Once we have suitable cavities, the next stage is filling.
 Filling & Checking Empty Cavities
Depending on the design of the blister packaging equipment, it will manually or
automatically fill the cavities with product. At the same time, the machine will also check
whether the cavities are empty or not.
Material filling station
 Blister Seal Station
In this section, there must be a proper coordination and timing between the two stations. That
is, by the time the forming film reaches this point, there should be lidding material already in
place. At this point, the lidding material will cover the forming film (with products). It will
cover the entire surface before it moves to the sealing station heating system.

60
Vegetable Slicing Machine:
The vegetable slicing machine has being utilized in reducing the varying sizes of vegetables.
The machine consists of two cutting blades, a vegetable feeder (hopper), a slicing/processing
chamber, two electric motors, and a discharge unit. Some certain factors such as safety,
power consumption, economic value and efficiency of cut have greatly informed the
modification of this machine to meet up with present demand. This machine is capable of
automating the cutting process increasing efficiency and enhancing the hygiene of slicing
vegetable for both domestic and commercial consumption.
Crown Corking Machine:
Vegetable Slicing Machine_____
Crown Corking Machine is a sort of hand press in which a
small cavity with magnet is made on the chuck to hold
Crown Cork. The bottle is placed on a specially built
plateform, so that Crown Cork head when pressed,
automatically comes in the Centre of Bottle. Bottle after
filling the Content is placed on the plateform and one
Crown Cork is Placed on the head, by simple hand
pressure the Crown Cork is pressed on the Bottle and
secured on the bottle making it leak proof. It gives a
prefect sealing and bottles can be preserved for long with
this method of Sealing. Once opened Crown Cork cannot
be used again.
Crown Corking Machine

61
Can Manufacturing Equipments:
Cans are manufactured daily at Alld Canning Ltd. to prevent any surface microbial growth
and cross contamination. The unit is capable of making 9,000-10,000 cans per day through
highly skilled workmen.
The can bodies may get collapsed due to transportation in distant areas. Therefore,
in order to reduce the space and easy transportation, the can bodies are shaped
into cylindrical form using can body reformer
The cylindrical shaped can bodies are flanged on other ends by flanger. The
equipment has two flanging dyes including grooves.
1. Can Reformer
2. Can Flanger

62
The seaming machine helps in closing ends of the can
The process of removal of air from can is known as exhausting
3. Double Seaming Machine
4. Exhaust Box

63
Vegetables (mostly non-acidic vegetables) are process under steam pressure enclosed retorts
known as automated pressure cookers
Processing of Canned Food:
Heating of foods for long term preservation is known as processing. In canning technology,
processing means heating of canned food at very high temperature to inactivate
microorganisms. But such drastic treatment affects the quality of food. Processing time and
temperature should be adequate to eliminate all bacterial growth. Moreover, over-cooking
should be avoided as it spoils the flavour as well as the appearance of the product.
Method: The sealed cans are placed in retort keeping the level of water 2.5 to 5.0 cm above
the top of the cans. The cover of the cooker is then screwed down tightly and the cooker
heated to specified temperature. Canned fruits does not require high pressure sterlisation sue
to low microbial load and hence they are placed into retort with open lid. However, this is not
practiced in case of vegetable products. The period of sterilization should be counted from
the time the water starts boiling. After heating for the required period, the cooker the cover is
removed and cans are taken out.
5. Canning Retort

64
PROCESSING CHART AT ALLD CANNING LTD.
S. No. Item Size
Processing Time
(in min)
Specified Temperature
and Pressure
1. Pineapple Slices A2½ Can 40 210 °F/ B. W.
2. Pineapple Slices 1 lb Tall 30 210 °F/ B. W.
3. Pineapple Chunks A2½ Can 35 210 °F/ B. W.
4. Litchi Whole A2½ Can 30 210 °F/ B. W.
5. Cherry in Syrup A2½ Can 30 210 °F/ B. W.
6. Cherry in Syrup 1 lb Tall 25 210 °F/ B. W.
7. Guava Tinned A2½ Can 25 210 °F/ B. W.
8. Mango Tinned A2½ Can 35 210 °F/ B. W.
9. Peach in Syrup A2½ Can 35 210 °F/ B. W.
10. Peach in Syrup A-10 Can 40 210 °F/ B. W.
11. Fruit Cocktail A2½ Can 30 210 °F/ B. W.
12. Fruit Cocktail 1 lb Tall 25 210 °F/ B. W.
13. Pears in Syrup A2½ Can 25 210 °F/ B. W.
14. All Juices A2½ Can 35 210 °F/ B. W.
15. All Juices 250 ml 35 210 °F/ B. W.
16. Tomato Puree A2½ Can 40 210 °F/ B. W.
17. Tomato Puree A-10 Can 50 210 °F/ B. W.
18. Tomato Paste A2½ Can 75 210 °F/ B. W.
19. Mango Pulp A2½ Can 40 210 °F/ B. W.
20. Mango Pulp B. Bottle 40 210 °F/ B. W.
21. Pineapple Pulp A-10 Can 50 210 °F/ B. W.
22. Mango Pulp Mixed A-10 Can 30 210 °F/ B. W.
23. Fresh Green Peas in Brine A2½ Can 40 240 °F/10lb
24. Fresh Green Peas in Brine 1 lb Tall 30 240 °F/10lb
25. Baby Corn in Brine 1 lb Tall 25 240 °F/6 lb
26. Sweet Corn Cream Style 400 gm
Can
100 245 °F/13 lb
27. Sweet Corn Cream Style A2½ Can 120 245 °F/13 lb
28. Sweet Corn in Brine 1 lb Tall 60 240 °F/10 lb
29. Sarson ka Saag 1 lb Tall 70 247 °F/14 lb
30. Potato in Brine A2½ Can 45 240 °F/10 lb
31. Bamboo Shoot in Brine 1 lb Tall 25 240 °F/10 lb
32. Baked Beans in Tomato
Sauce
1 lb Tall 85 243 °F/ 12 lb
33. Beans Dried Curried A2½ Can 110 247 °F/14 lb
34. Black Channa Curried A2½ Can 135 247 °F/14 lb
B. W. =Boiling water pressure (1 atm.)

65
Lacquer Coating on Can Surface
Tin cans are made of thin stel plate of low carbon content, lightly coated on both sides with
tin metal. Since, it is difficult to coat the steel plate uniformly, when filled with product, the
content of may react with these uncoated spots resulting in discolouration of the product or
corrosion of tin plate. It is therfore necesary to coat the inside of can with some material
(such as lacquer) which prevent this issue and does not affect the flavour or wholesomeness
of the contents. This process is called ‘Lacquering’.
At Allahabad Canning Ltd., two types of lacquer coatings are used:
1. OSL (Outside Sulphur Lacquering)
This lacquer is of golden colour and cans coated with it are also called as C-enamel or
S.R. (Sulphur Resistant) cans. They are meant for non acidic or very low- acidic food
products as they react with cans spontaneously affecting the sensory characteristics of
product being filled inside the can.
Generally, these cans are used for pea, corn, lima bean, red kidney bean etc.
2. ARL (Acid Resistant Lacquering)
Acid Resistant Lacquer is also golden coloured enamel and cans coated with it are called
R-enamel or A. R. (Acid Resistant) cans. These cans are used for packing acidic fruits
which are of two kinds:
(a) those whose colouring matter is insoluble in water.
e.g., peach, apricot, grapefruit etc.
(b) those in which added colour is water soluble.
e.g., raspberry, strawberry, red plum, grape etc.
Fruits of group (a) are packed in plain cans and those of group (b) in lacquered cans.

66
Steam Jacketed Kettle:
The steam jacketed kettle or evaporating pan is an evaporator that can be used for the bulk
evaporation of water from aqueous liquids. It is constructed in the form of a hemispherical
shaped shell usually made of stainless steel that is comprised of an inner pan or ‘kettle’ and
an outer pan or ‘jacket’. Steam flows through the space between the outer and inner pans at a
slightly elevated pressure. The hot steam causes heat to pass through the inner pan, by
conduction, to the solution that is to be evaporated. As the temperature of the solution rises,
so solvent molecules are evaporated. The pan can be permanent mounted and the product is
emptied through an outlet at the bottom of the pan, or the pan can be mounted in such a way
that it can be tilted so that the product can be poured out.
Now-a-days, these kettles are also equipped with metal stirrer to facilitate uniform mixing of
product while cooking.
Steam Jacketed Kettle Steam Jacketed Kettle
with stirrer
Steam Jacketed Kettle (Original photo)

67
Boiler at Allahabad Canning Limited
Boiler is meant to generate profits. For this, Allahabad Canning Ltd. has installed boiler with
combining benefits of Water Tube and Smoke Tube designs, HYPAC from Cheema Boiler
Ltd, Punjab, the most proficient and economic offering to the industry with capacity of around
2 tonne steam generation per hour. Its Smoke Tube portion has a large water holding capacity
along with a large water-steam interface area. This ensures a longer life for the boiler and
increases efficiency alongwith safe operations of the machinery.
The Water Cum Smoke Tube boiler offers the following advantages:
1. Low fuel consumption:
 Minimum heat loss due to membrane type water wall design.
 Option of in-bed coils in the furnace.
 Most efficient combustion with optimum residence time of flue gases in the
furnace.
 Better heat transfer and longer tube life due to optimum velocities in smoke
tubes.
 Variable frequency Fuel Feeder (VFD) for complete combustion of fuel.
 Swirling air injection for better post combustion burning of fuel.
Labelled diagram of Water cum Smoke Tube Boiler
2. Reduces Maintenance Cost:
 High efficiency low speed fans.
 Minimum refractory work.
 Reputed brands of mountings and accessories.

68
 Anti-abrasive filling in the cyclones.
 High grade casting fire doors.
 High quality electrical components.
3. Reduced Power Consumption:
 Energy efficient boiler component of reputed brands.
 Optimum resistance of flue gas path.
Labelled description of process carried out in boiler
Other advantages includes
 Multi fuel option- making it an ideal investment.
 Specially designed fluidised bed combustion furnace- well suited for burning
fuel like rice husk, sawdust, groundnut shell, DOC (De-Oiled Cake), coal,
baggase, pet coke, coffee, husk, wood chips, soya chunks etc.
 Combination fuel options-e.g., oil/gas and solid fuel.
 Quick fuel switching with minimum adjustment.
 Centralised instrumentation and electrical control panel.
 Option for step less pressure control.
 Automatic water level control and safety systems.
 Easy ash handling with option of continuous ash discharge.
Environmental benefits
 The HYPAC water cum steam tube boiler is equipped with Ai r Pollution
Control System making it a highly eco-friendly.
 Most Suitable for renewable fuels.
 Efficient heat recovery unit.

69
Waste Water Treatment Plant at Allahabad Canning Ltd.
Water is considered the “life blood” of any facility for the simple reason that it transfers heat
from one location to another. A complete water treatment program has one goal in mind, to
manage the efficiency of that heat transfer. Water treatment is an important industry
requirement and comes under four main branches which include boiler water treatment,
cooling water treatment, water purification and the treatment of wastewater effluent.
Primary considerations in waste water treatment
 Control of corrosion
 Control of scaling
 Control of microbiological fouling
 Control of general dirt and debris
Process flow chart:
Water mixed with chemical effluents
Primary Cleaning Tank
Addition of:
Calcium Carbonate (pH maintaining agent)
Alum, DAP, Urea, Jaggery (for Microbial culture preparation)
Addition of flocculating Polymer
Primary Clarifier
Secondary Cleaning Tank
Secondary Clarifier
Final Cleaning Tank
Filtration
pH measurement
Cleaned water gets discharge for irrigation
use

70
Process carried out for waste water treatment

REFERENCES:
 Canned Fruits and Vegetables, CFTRI, Mysore
 Canning of Fruits, B. S. Luh, C. E. Kean, and J. G. Woodroof
 Cherry Production Technology, IARI, New Delhi
 Fruit and Vegetable Preservation, R P Srivastava
 Fruit and Vegetable Processing, ANGRAU
 Fruit Jam Slices, CFTRI, Mysore
 Fruit Squashes and Syrups, CFTRI, Mysore
 Industrialisation in India, 1850-1947: Three Variations in the Emergence of
Indigenous Industrialists, Gijsbert Oonk
 Litchi study, A report on status of food processing industries in Bihar
 Mango Processing and Processed Products Md. Siddiq, Dalbir S. Sogi and Sunisa
Roidoung
 Morton India E brochure www.mortonindia.com
 Preparation of Value-Added Products Through Preservation M. Preema Devi,
N. Bhowmick, M.R. Bhanusree, and S.K. Ghosh
 Selecting, Preparing, and Canning Fruit and Fruit Products, US FDA
 Tomato Sauce, Ketchup and Puree, A model project on Tomato processing

In-Plant Training Report at Allahabad Canning Limited

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to In-Plant Training Report at Allahabad Canning Limited

Similar to In-Plant Training Report at Allahabad Canning Limited (20)

More from Abdul Rehman

More from Abdul Rehman (20)

Recently uploaded

Recently uploaded (20)

In-Plant Training Report at Allahabad Canning Limited