Presented by:- SARIKA DEVI SUMIT SAHGAL SHOBHA
Britannia Industries Limited(BIL)
In 1892, with an initial investment of 295 in Kolkata.
During the tragic World War-II, the Government reposed its trust in Britannia by contracting it to supply large quantities of "service biscuits" to the armed forces.
Leadership position in Indian bakery market with 124 billion.
Market share of ~38% in the industry.
It has an annual production capacity of 433,000 tonnes and has got 600,000 outlets across India.
In International markets over 30 Countries and a number two brand in the UAE and Oman.
BRIEF ABOUT UTC
Production trail started on 1st April 2005 in Rudrapur.
Total plotted area of approximately 20 acres.
the purpose of production of biscuits as this area is free from all types of taxes.
New concept like 5S
The Company is perusing for ISO 14001 certificate and it is ISO 22000 certified.
This unit enjoys the excise and income tax benefit from Uttarakhand government.
GLUCOSE BISCUITS BRITANNIA TIGER
MARIE BISCUITS BRITANNIA MARIEGOLD, NUTRICHOICE
COOKIES GOOD DAY BUTTER, GOOD DAY CASHEW, GOOD DAY PISTA BADAM
CRACKERS 50-50 CHASKA-MASKA
CREM BISCUITS TREAT(orange, pineapple, strawberry, fruit)
MACHINES & AREA
Hot water generator
Chocolate melting tank
Butter melting tank
Load cell (Butter)
Lecithin, Solbake, GMS paste preparation tank
SMP Solution tank
Filter for invert syrup
Invert syrup solution tank
Sugar syrup solution tank
Sugar grinder (Manual)
Automatic sugar grinder tank
Flour sampling sieve
Weighing balance (Heavy)
Atta sifter sieve
Bran sifter sieve
Lift for uplifting materials.
Butter, HVO store area.
Cold store for nuts.
Cold store for flavor
Sugar storage area.
Flour storage area.
General store office
Shelf life room
WHEAT FLOURWATERSUGARFAT &OILSALTFLAVOURMILK & MILK PRODUCTLEAVNING AGENTEMULSIFIERCOLOURWheat Flour
Principal ingredient in Bakery products.
Unique ability to form Gluten.
Gluten is made of Gliadin & Glutenin (Insoluble Proteins).
Soluble proteins present in wheat flour are Albumin & Globulin.
Gluten is elasticlike and forms matrix.
Gluten forms only on mixing with water.
Gliadin contributes to elasticity & Glutenin imparts strength (Resistance).
Both quantity & Quality of gluten are important in assessing the strength of flour.
2nd major ingredient in Bakery products.
Hydration of proteins.
Acts as a dispersion medium for sugar & other chemicals.
The consistency of dough largely depends on water.
An excellent leavening agent.
Medium hard water is preferred for most of the Bakery products, as some of the mineral salts (like Calcium salts) have a strengthening effect on gluten and some (like Ammonium salts) serve as yeast foods.
FATS & OILS
Act as lubricants.
Provides texture/structure to the product.
Act as aerating agents.
Eating quality (Palatability).
Moisture-barrier in finished products.
Particle size of sugar greatly affects baking properties.
MILK & MILK PRODUCTS
Flavor and taste contribution.
To enhance crust color and bloom.
To improve tenderness of the product.
To improve the texture without altering the symmetry and crumb color.
To reduce the greasy feeling in sandwich creams.
As an alternate to eggs (use of whey protein concentrates).
Dispersibilty in water or fat as per requirement
Expression/Stability at the product pH.
Compatibility to the product as the expression of flavor generally varies with the fat content in the product.
Masking any undesirable odour from the product.
Closeness to the natural product envisaged.
To provide identity to the food product.
To provide variety to the consumer.
To correct the natural variations in the color of the food.
To enhance the natural color but at levels lower than that usually attached to the given food.
To protect food products, flavors and vitamins that can be affected by exposure to light.
Starch complexing (anti-staling)
Protein complexing (Dough strengthening)
Foaming and aeration
As Wetting agents & solubilisers.
Suspension & dispersion.
Rise the volume of dough
Baking powder contains baking soda and the right amount of acid to react with it.
Batters made with double acting baking powder rise twice;
once when dry and moist ingredients are mixed together, and again when the product is baked.
Above 70 C, it gradually decomposes into sodium carbonate, water and carbon dioxide. The conversion is fast at 250 C 2NaHCO3 Na2CO3 + H2O + CO2Leavening agents where in application low final moisture content is reached in baked products such as cookies and crackers. NH4HCO3 NH3 + H2O + CO21-S.B.C.(Sodium bicarbonate) 2-A.B.C.(Ammonium bicarbonate) 1) Wheat flour
2) Palm oil:
% Moisture: 14 (max.)
% Total ash: 0.8 (max.)
% Acid insoluble ash: 0.05 (max.)
% Alcoholic acidity: 0.12 (max.)
% Gluten on dry basis: 7.5 (min.)
Germ oil acidity (as oleic): 15 (max.)
Granularity : 85 mesh sieve ( 99% should pass through )
Sedimentation value : 17 to 30
Taste and colour : should be characteristic
Extraneous matter : should be absent
Origin : should be of vegetable origin
% FFA -0.10 max. (as oleic acid )
% Moisture: 0.10 (max.)
Peroxide value: 1.5 (max.)
Refractive index : 1.4491- 1.4552
Saponification value : 195 205
Unsaponifiablematter: 1.2 %( max.)
Iodine value : 45 56
Melting point: 37 C (max.)
% Moisture : 0.1
% Total sugar : 99.5
SO2 : 70.0ppm
ACCEPTANCE CRITERIA FOR INGREDIENTS
Material receivingPremixing CreamingMixingMoulding
BISCUITS GRINDING MACHINE
NUT SHORTNING ROOM
INVERT SYRUP PREPARATION
C:\Users\trikx005.KRFT\Desktop\Pic- 9th dec\20131211_121255.jpgSIEVE
LECITHIN PASTE PREPARATION
1 Kg Lecithin + 3 Kg HVO
Mixture dumped to Lecithin Paste Preparation Tank
Steam from boiler
Mixture melts and ready to be used BUTTER PREPARATION
Butter melting tankFilter Load cell Storage tankMixture
SKIM MILK POWDER(SMP) PREPARATION
75 Kg of SMP
150 Kg water
Solution prepared & ready to be used in the mixer MIXING
Then it is mixed with other ingredients for further 2 minutes. SIGMA ARM MIXTURETo entrap air and to mix all ingredients.
It involves mixing of fat, sugar, flavour except flour, creamed for 8-12 minutes.
Mixing time is around 2 min. Benefits of Continuous Mixing
Simplifies the mixing process
Disperses ingredients consistently
Simplifies dough feed equipment
Provides tight control over the mixing process
Is safer , more sanitary and can be operated with less labour and energy than batch mixing
Is easy to sanitize, maintain, clean and inspect due to the clamshell design
No dough contamination because the dough is never exposed to the environment
Is easy to operate due to the user friendly controls
Controls ingredient metering to the mixer so its precise and uninterrupted.
Dough is prepare
A-Forcing roller C-Extraction roller E-Extraction web H-Hopper B-Moulding roller D-Scraper(Knife) F-Cleaning scrapper CUTTING
The zones are classified as: There are 7 independent zones in all three plants. These are
a) Proofing zone: zone 1 & 2 (Structure is set here)
b) Puffing zone: zone 3 & 4 (Product get oven spring)
c) Baking zone: zone 5 & 6 (Moisture removal of product) d) Colouring zone: zone 6 & 7 (Millard & Caramlization)The Physical changes
The Chemical changes
Large reduction in product density.
Development of an open porous or flaky structure.
Change of shape associated with shrinkage