Project report

1. Report on Industrial Training
At
United Biscuits Pvt. Ltd., Kala Amb
Submitted by-Chalsi Thakur
Period- 13th August- 13th September, 2021
DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY,
UNIVERSITY COLLEGE, CDLU SIRSA

2. INDEX
1. Acknowledgment - Slide No.-3
2. About Pladis Global- Slide No.-4
3. Flowchart-Manufacturing of Biscuit- Slide No.-5
4. Brief of Process Flow chart- Slide No.-6-8
5. Variants Manufactured- Slide No.-9
6. Quality inspection of RM& PM- Slide No.-10-21
7. Conclusion- Slide No.-22

3. ACKNOWLEDGEMENT
The one month training, part of my curriculum, at United Biscuits was like a dream come true. The
renowned biscuit manufacturing company provided me a platform to present myself. I would like
present vote of thanks to Mr. Anil Johri(Director Manufacturing, U.B. Kala Amb), under whose
leadership, this unit is running and achieving new milestones daily. I would like express my
gratitude towards Mr. Rajinder Singh(Manager, H.R.), who allowed me to have my internship over
here. He is man with a golden heart & down to earth personality, who taught me many skills &
always appreciate one who is keen to learn. I would like to thank all the quality department
members where I was deputed to learn. Mr. Abhinav(Jr. Officer, NPD), taught me the technicality of
trials & introduction of New Products. I can’t forget one person Mr Sayed Rizvi(Mixing Executive),
who taught me process & technical background of it.
This one month training has helped me to improve myself and understand the industrial structure
and process much better.

4. ABOUT PLADIS GLOBAL
• PLADIS is one of the world’s leading snacking companies. We are the proud
steward of over 300 years of family baking and confectionery experience,
and home to the some of world’s most loved snacking brands,
including McVitie’s, Ulker and GODIVA.
• About United Biscuits Pvt. Ltd.
• United Biscuits (UB) is a British multinational food manufacturer,
makers of McVitie's biscuits, Jacob's Cream Crackers, and Twiglets. The company
was listed on the London Stock Exchange and was once a constituent of the FTSE
100 Index. In November 2014, the company was acquired by Yıldız Holding and is
now part of Pladis.

5. FLOWCHART:
MANUFACTURING OF
BISCUIT

6. BRIEF OF PROCESS FLOW CHART
• 1. Receipt of Raw & Packaging Material-
• Raw Material purchased by Procurement team is delivered at factory through
different transportation means as per requirement and dedicated timelines.
• 2. Quality inspection of received material-
• Quality inspection of received material is done by Technical team as per SOP's.
• Below are the different tests done of the received material.
• 3. Material storage in stores-
• Approved material by technical team storage is done in stores. Separate stores are
available for sugar, wheat flour, 20 degree Celsius storage area & 0 degree Celsius
storage area.

7. 4. Dough batch making-
Dough batch making involves below mentioned steps-
a. Material is weighed on the second floor of the mixing section
b. Chemical portion is added to Shear mixer and thus transferred to Creamer
c. Chemicals, sugar, RPO & invert sugar syrup is mixed in creamer & process is called Creaming
d. Cream is transferred to Mixer & wholewheat & wheat flour is added and mixing of batch is done.
5. Moulding/cutting of batch at Rotary-
a. Dough batch from mixer to Rotary is transferred through hoppers.
b. Moulding of short dough is done using moulder
c. Cutting of the hard dough varieties is done using laminator, roll reduction & cutter
6. Baking-
-Mould/cutt dough is baked with the help of set of ovens. Factory has two lines with 7 & 6 oven chambers named
as Line-1 & 2 respectively.
- Baking is done using three modes of heat transfer i.e. conduction, convection, irradiation
- Baking of biscuits involves specific protocol of Baking time & temperature combination.
- Baking profile has a parabolic path which is defined as three stage baking- Baking, puffing , coloring
- Baking oven has turbulence, MCH, burner as its key parts

8. 7. Cooling : During cooling, the flexible structure becomes rigid as sugar and fat solidify, Cooling
should be extended as long period as possible and the humidity of the cooling
atmosphere should be controlled. There are two systems of cooling followed.
Atmospheric multi-tier conveyor
In the atmospheric multi-tier conveyor, the biscuits from the oven band travel on to
a canvas web having single, double or three tiers. The biscuits on these are cooled
by surrounding atmosphere.
8. Packaging : Post cooling of the biscuits, they are packed in different packing options. Laminate
always serve as a primary packaging material(In some cases, along with tray). Secondary packaging is
done in the form of monocarton/CDU/Polybag. Shipper serves as a tertiary packaging material.
9. Dispatch : Packed material is kept in dispatch area. As per market requirement and capacity of
storage area, finished goods are either moved to market directly or shifted to CFA’s.

9. VARIANTS MANUFACTURED
• Digestive Fruit cookies
• Digestive Mini Ginger cookies
• Digestive Light Hobnobs
• Digestive 7 Grain
• Butter cookies
• Cashew cookies
• Marie
• Wholewheat Marie
• Rich Tea
• Dark cookie cream
• Bourbon Cream
• 5- Grain Cracker
• Cheese Cracker

10. QUALITY
INSPECTION OF
RM & PM
• TO CHECK ALL THE QUALITY PARAMETERS OF THE
RAW MATERIALS/INGREDIENTS USED FOR
THE FINISHED PRODUCTS
• Along with raw material handling Q.A department also checks
or controls all process parameters on shop floor like –biscuit
moisture, stack height, length, width, weight, colour, baking etc.
• • Maintain packing material (wrapper,polybag-Box) standards as
per the requirement.
• • The department carries on time to time checking and control
of qualitative parameter of finished goods are :
1. WHEAT FLOUR
2. REFINED PALM OIL
3. SUGAR
4. BISCUITS
5. PACKAGING MATERIAL

11. CONTD...
• Flour used in biscuit making should be free flowing, dry to
touch, free from visible bran particles, creamy in color,
free from musty flavor and rancid taste, fungal infection and
other contaminationsIt is a raw material. The following tests for
maida are done on daily basis.
• Soft Wheat flour is used for following reasons:-
• Soft wheat flour is used because it will gives more tender
biscuits then hard wheat flour.
• The flow or spread of biscuits dough during baking is taken as a
measure of the flour. Quality is much greater using soft wheat
flour.

12. CONTD..
Tests of wheat flour :
• It is primary raw material
• Most biscuits are prepared from flour-which has low quantity of
protein and weak extensible gluten
• Soft and medium hard flour(protein content 8-11%) is used which
gives gluten that is less resistant to deformation
• More extensible
• Dough is rubbery

13. MOISTURE
CONTENT OF
MAIDA
• Take a dry petridish and note down its weight.Now put about
5gm of Maida in it. Keep it in the oven at 130 Celsius for 2 hours
and cool it in dessicators. Now take the weight of dish.
• Moisture content = {(M1 – M2)*100}/Sample weight
• M1= weight before keeping in oven
• M2= weight after keeping in oven
Importance of test
• Wheat or flour with high moisture content (greater than 14.5
percent) attracts mold, bacteria, and insects, all of which cause
deterioration during storage.Thereby affecting the shelf life.

14. TOTAL ASH
CONTENT
OF MAIDA
• Take an empty crucible and note down its weight. Now weigh
about 5gm of sample in it and keep it on gas burner until
sample is carbonized (starch ,protein evaporates) for 1 hr.Now
take out this crucible and keep it in the muffle furnace(550
celsius)for 4 hrs.
• Total ash content = {(weight of crucible with ash – weight of
empty crucible)*100}/sample weight
Importance
• Basically ash is an inorganic material (contains minerals).High
content of ash in maida can produce health related problems
like kidney stones. Ash in flour can affect color, imparting a
darker color to finished products.

15. GLUTEN
CONTENT
OF MAIDA
• Take about 25gm of sample in a beaker and take water(25ml) in a
burette. Add water to the maida dropwise till a dough is formed. Put
this dough in water for 1hr.Now remove the starch manually from
the dough by rubbing it in water.In order to check the presence of
starch put a drop of iodine on dough if it turns blue then maida has
starch otherwise not. Now take a butter paper and note down its
weight. Make small pieces of dough and put it in the paper and keep
this in the oven for 2hrs (130 celsius). After this cool the paper and
sample in dessicators then note down the weight. The wet cohesive
mass obtained is wet gluten while the dried product obtained from
it is called dry gluten.
Importance
• The elastic nature of dough is attributed to gluten proteins namely
gliadins and glutenins. The gliadins impart extensibility to dough,
whereas glutenins is held responsible for strength and elastic
character of gluten and dough. It helps to understand the gluten
content in flour and thereby selection of flour as per the product to
be manufactured. The more the gluten is developed, the tougher
and chewier the baked good.

16. SEDIMENTATION
VALUE OF MAIDA
• Take 3.2gm of maida to it add 50ml of distilled water and add a
few drops of bromophenol blue indicator. Now put this in a SV
tube and put it in the shaker for 5 mins.Now remove it and add
few drops of lactic acid.Again shake for 5 mins and then let it
settle for 5 mins. Note down the reading from the measuring
cylinder.
Importance
The higher the quality of gluten is, the more the swelling in flour
particles is, the later the sedimentation of the swollen particles is
and the higher is the sedimentation value. SV is the simplest
method to determine the Quality and Quantity of protein (gluten)
according to their ability to swell and settle in a slightly acidic
medium.

17. TESTS OF
RPO
(REFINED
PALM OIL)
• It contributes to taste, heat stability, resistance to oxidation,
texture and smoothness. Importantly, palm oil virtually contains
no trans fatty acids. In recent years the replacement of partially
hydrogenated vegetable oils, a source of trans fatty acids, has
led to an increased use of palm oil to lower trans fatty acids in
foods. No other vegetable fats naturally solid at room
temperature and providing the same features exist in sufficient
quantity
• Antioxidant test; Take 5ml RPO add 5ml of methanol then shake
the mixture vigorously.Now add 5ml of Dimethylamine solution.
If red color appears then antioxidants are present otherwise not.
Importance
Used as preservatives. Prevents the oxidation of oil which can lead
to rancidity.
FFA test (free fatty acid) of RPO; Take 10gm sample and add
neutralized alcohol in it.Add phenolphthalein as an indicator.
Titrate the mixture against NaoH till pink color disappears. Note

18. Ffa value = 100 x Normality of NaoH(0.1001)x Titre Value x eq. Wt (282).
Weight of sample x 1000
Ffa value is found out in terms of oelic acid.
Importance; Fats and oils are graded by their acid and free fatty acid (FFA) contents, which are
used as an index to determine their quality. Palm oil contains by higher proportion more of
the saturated fatty acids. A high content of free fatty acids in palm oil results in a fermented
like smell.

19. DETERMINATION OF
ACIDITY OF
EXTRACTED FAT
APPARATUS:
• Soxhlet apparatus, with a 250 ml flat bottom flask
• BY SOXHLET EXTRACTION METHOD
• Extraction: The extraction chamber is filled up with condensed
solvent. As soon as the solvent reaches the optical sensor, the
chamber is emptied by opening the valve unit.
• Rinse: The valve unit is always open, which allows the
condensed solvent to rinse the sample.
• Drying: The solvent is evaporated and collected in the water-
cooled tank at the back of the instrument, which allows it to be
re-used for further extractions. The tank valve is open.
• After completion of the extraction, the beakers containing the
extract have to be removed and dried to constant weight

20. REAGENTS:
Petroleum ether, boiling point 40°C – 60°C.
Benzene-alcohol-phenolphthalein stock solution - To 1 L of distilled benzene add 1 L of alcohol or
rectified spirit and 0.4 g of phenolphthalein. Mix the contents well.
Standard potassium hydroxide solution, 0.05N
PROCEDURE:
Take a thimble and cover the top with cotton and note down its empty weight.Take 20gm sample In
thimble and note down the weight.Extract the fat in soxlet apparatus for 3-4 hrs evaporate off the
solvent in the flask.Keep flask with fat in oven for 1 hr.Cool it down and note down the weight of dried
flask. Calculate the fat %. Now add 50ml of ethanol in fat and add phenolphthalein blue as indicator,
titrate it with 0.05 NaoH end point is appearance of light pink color.
CALCULATIONS:
Acidity of extracted fat = 1.41 x Titre Value
Weight of extracted fat
Where;
Weight of extracted fat = Weight of RBF after drying – Weight of RBF before drying
Fat % = Weight of extracted fat x 100

21. TEST OF PACKAGING MATERIAL
CBB/ CFB (corrugated fibre or brown box); Tests include
Art work identification wrt to a original box (used as reference).This is done to see that every printed
material has the same configuration as the original box. Eg checking of logo, address of company, no.
of packets on written on the box.
Printing defects identification, done in order to see that whether there is any smudging of ink on the
box.
Moisture content checking test. If the moisture content is very high the final boxes may not be
stacked properly.
Compression strength test. To determine the stack length
Dimension identification is done to see that whether the length breadth or height of the box is within
the limits of standards set by the industry.
The GSM test is a measurement of Grams per Square Meter, and is one of the most important
methods of determining the weights of boxes. GSM provides the weight per unit area.
Trays; Test include identifying the dimensions, GSM test, weight of 10 boxes.
Polybag testing; Measuring the length,breadth and thickness, calculating count per kg(unitary
method), weight of 10 bags.
Thickness = 3300*(avg. wt, of one bag)/area in square inch

22. CONCLUSION
Overall, Internship is a really good program and recommended to my fellow friends,
It helps me to enhance and develop my skills, abilities and knowledge. It was a
good experience and memories as not only I have gained experience, but also new
friends and knowledge. United Biscuits also a good place to do the internship since
it provide numerous benefits and advantages to the practical trainees.