Manufacturing and processing of Parle G - The world's largest selling biscuit.

1. MANUFACTURING &
PROCESSING OF
PARLE-G BISCUITS
SUBMITTED BY: MRIDULA
BHANDARI

2. CONTENTS
 Introduction
 Logo
 Products range
 Overview: Parle Pvt. Ltd, Rudrapur
 Working Structure : 5’S Policy
 Production Unit Flow Chart
 Inventory management
 Raw materials
 Process layout of Parle-G biscuits

3. CONTENTS (CONTD.)
 Coding
 General data for Parle-G
 HACCP
 GMP
 Conclusion

4. INTRODUCTION
1. Industry : Food
2. Founded : 1929
3. Headquarter : Vile Parle (East), Mumbai
4. Parent : Chauhan family
5. Products : Biscuits, Snacks & Confectionary
6. Revenue : $977.24M
7. Net income : $39.55M

5. LOGO
 Red color denotes hunger & health
 White color denotes purity & goodwill.

6. PRODUCTS RANGE
 The company is associated with the
manufacturing of a wide variety of biscuits and
confectionary items:
 Biscuits: Parle-G, Monaco, Krackjack, Hide &
Seek, Golden arcs, Golden kreams, Parle 20-
20.
 Confectionery : Poppins, Melody, Mango bite,
Eclairs, Kismi bar
 The Pantnagar plant is involved in
manufacture of Parle-G, 20-20, Happy-Happy,
Orange Kreams.

8. OVERVIEW: PARLE PVT. LTD. ,
RUDRAPUR
 Established in 2005 over a vast area of 13 acres
 Boasts Asia’s largest oven
 Average production is 5,000 metric ton per month
 56 officials and 910 workers
 There are 3 plants in the unit as follows:
1) P1- Cookies (Happy-Happy, 20-20)
2) P2 - Parle-G
3) P3 - Orange kream biscuits

9. WORKING STRUCTURE: 5’S
POLICY
5’S Policy
 Seiri- Reorganization
 Seiton -Neatness
 Seiso - Cleanliness
 Seiketshu - Standardisation
 Shitsuke – Discipline

10. PRODUCTION UNIT
FLOWCHART
Raw material section
Mixing section
Rotary and moulding section
Baking section
Cooling and stacking section
Packaging and dispatch section

11. INVENTORY MANAGEMENT
 Inventory management is primarily about
specifying the size and placement of stocked
goods.
 Required at different locations within a facility
or within multiple locations of a supply
network.
 To protect the regular and planned course of
production.
 It is about knowing where all your stock is and
ensuring everything is accounted for at any
given time.

12. INVENTORY CHECKPOINTS
FOR RAW MATERIAL STORES
 FSSAI Lic. No. should be mentioned in invoice
copy as well as in their bags and boxes of each
and every materials.
 Food grade statement should be mentioned in
invoice copy.
 COA report are attached with every consignment
and every report should be clear as per the norms
of FSSAI
 Manufacturing and expiry date should be
mentioned.
 All materials loaded/unloaded in neat and clean

13. INVENTORY CHECKPOINTS FOR
RAW MATERIAL STORES
(CONTD.)
 All RM/PM issued as per the FIFO/FEFO for
maintain better inventory storage system.
 Covering all RM/PM for reducing contamination
and maintain hygiene of the material products.
 Scrap materials left-ups as per the given time
duration.
 Identification boards are updated according to
RM/PM for Maintain FEFO/ FIFO of the material
vehicle verification as per verification list.
 FIFO - First In First Out
 FEFO- First Expiry First Out

14. RAW MATERIALS
 Maida (wheat flour)
 Finely milled wheat flour
 Becomes cohesive, elastic and gas retenting
when hydrated and kneaded.
 In presence of water forms gluten which is
responsible for above properties.
 Acts as a structure builder.

15. RAW MATERIALS (CONTD.)
 Sugar
 Responsible for structure and hardness in
short dough biscuits
 Aids surface coloration
 Enzyme carrier
 Invert Syrup
 Prevents surface crystallization
 Gives colour and helps in moisture retention

16. RAW MATERIALS (CONTD.)
 Salt
 Modifies other flavours
 Affects the rheology of dough and improves the
dough crumb colour.
 Water
 Acts as solvent to form dough
 Acts as a leavening agent and helps in
expansion.

17. RAW MATERIALS (CONTD.)
 Skimmed milk powder (SMP)
 Provides nutrients to product
 Used as a minor dough ingredient to give
subtle flavour and textural improvements to aid
surface cooling.
 Ammonium bicarbonate (ABC)
 Leavening agent
 Maintains the stack height of biscuits.

18. RAW MATERIALS (CONTD.)
 Sodium bicarbonate
 Self contained leavening agent
 Adjusts the acidity of dough and taste of
biscuit
 Puffing activity
 Sodium meta bisulphate (SMBS)
 Used in very small quantities as a preservative
and to modify gluten quality chemically

19. RAW MATERIALS (CONTD.)
 Lecithin
 Acts as an natural emulsifier
 Finamul
 Is an artificial emulsifier
 Vanilla flavour
 Artificial flavour induces the characteristics
flavour into the biscuits

20. RAW MATERIALS (CONTD.)
 Parle Flavour Mix
 It is added in Parle G dough. It has maturation
time of 1 month so is used 1 month after the
date of manufacture.
 Propylene Glycol
 Mixed with Parle flavour in PFM tank to make
flavour.

21. PROCESS LAYOUT OF PARLE
BISCUITS
Parle-G biscuit plant consists of different units
to perform various works, they are as follows-
 Raw materials storage
 Maida sugar section
 Mixing unit
 Rotary unit
 Oven
 Cooling
 Packaging unit

22. 1. RAW MATERIALS
STORAGE
S.NO. COMMODITY HOLDING TIME STORAGE CONDITIONS
1. Maida 15 days Room temperature
2. RBD 1 Month In silo at 40-45°c
3. Sugar 1 Year Room temperature
4. SMBS 9 Months Cool and dry place
5. SMP 9 Months Cool and dry place
6. SBC 3 Years cool and dry place
7. ABC 9 Months Room temperature

23. 1. RAW MATERIALS STORAGE
(CONTD.)
S.NO
.
COMMODITY HOLDING TIME STORAGE CONDITIONS
8. Salt 2 Years Cool and dry place away from sunlight
9. MACP 2 Years Cool and dry place away from sunlight
10. Finamul P-4107 1 Year Cool and dry place at room
temperature
11. PFM 1 Year At room temperature and dry place
away from sunlight
12. Citric acid 2 Years Cool and dry place at room
temperature
13. Lecithin 1 Year Dry place away from sunlight
14. Orange flavor 1 Year At room temperature cool and dry
place away from sunlight

24. 1. RAW MATERIALS STORAGE
(CONTD.)
S.NO
.
COMMODITY HOLDING
TIME
STORAGE CONDITIONS
15. Cardamom flavor 1 Year Cool and dry place away from
sunlight
16. Liq.vanilla flavor 1 Year Cool and dry place away from
sunlight
17. Condensed milk 1 Year At room temperature cool and dry
place away from sunlight
18. Sunset yellow 5 Years At room temperature cool and dry
place away from sunlight
19. Propylene glycol 2 Years At room temperature
20. Ethyl vanillin powder 5 Years Cool and dry place away from
sunlight
21. Vanillin powder 5 Years Cool and dry place away from
sunlight

25. 2. MAIDA SUGAR SECTION
 Both maida and sugar are stored in large
vertical tank. RBD is stored in vertical silo.

26. 3. MIXING UNIT
 Powder vessel - Receives 110kg of maida per
batch from maida service tank through
pipelines.
 Creamer vessel - Receives Ghee, Powdered
sugar, skim milk, Palm oil from RBD through
pipeline at temperature 40-45°C.
 Powdered sugar is passed through vessel and
SMP is provided to the creamer vessel.
 Finamul is used as emulsifier mixed with Palm
oil.
 CV agitator is attached to the vessel to agitate
the ingredients properly.

27. 3. MIXING UNIT (CONTD.)
 Liquid vessel - Receives Soda, Salt, Ammonia, Sugar
Syrup, PFM (Parle flavour mix) ,and water. SSA is
provided to vessel. Temperature of sugar syrup should
be about 42°C.
 Stephan Mixer - An ideal component to fully
automatically feed the downstream make up equipment
for biscuits.
 There are two types of motor attached to mix all material
- Baffle motor and Mixer motor.
 Rotation is about 600-700 revolutions.
 The operation divided into four phases: loading, mixing,
kneading and discharging, leads to a delicate crumb and
an extremely machine able dough.

28. CREAMER VESSEL LIQUID
VESSEL

29. STEPHAN MIXER

30. 4. ROTARY UNIT
 Has rotary blades which rotates and mix the dough to its
final stage.
 Dough temperature is about 33.5°C.
 Roller rolls the dough and cutting knife helps in cutting the
dough so that dough should pass from roller die
equivalently and each cup of die receives appropriate
amount of dough to form biscuits.
 Roller Die drum has 12 cups in circle and 31 cups in length
of the die drum.
 Die gives the shape and size to biscuits and imprints the
name of product i.e. Parle-G on top of the biscuit.
 After these biscuits are passed on to rotary belt they are
conveyed up to oven and are passed on the wire band belt
in oven.

31. 5. OVEN
 Propane gas is used as fuel. Width of the oven
is 54.5 inches and its length is 728 ft.
 Total length of oven is divided in three zones
i.e
Puffing zone 30% of total length.
Baking zone 40% of total length.
Colouring zone 30% of total length.
 There are damper plates at each zone of oven
whose opening and closing maintain the
steam inside the oven.

32. 5. OVEN (CONTD.)
 In first three zones damper plates are 20% to 30%
open to maintain the steam in oven for better puffing
of biscuits. In zones 4, 5, 6 & 7, the damper plate is
open about 40% to 60%. Here the biscuits are baked
and temperature is also high. In last three zones i.e.8,
9 &10, the damper plates are almost totally opened to
release all steam from the oven.
 Zones number 6, 7&8 are known as CCP zone. Their
minimum temperature is 230ºC-320ºC.
 It is most important zone among all other zones
because it maintains shelf life of the biscuits.
 CCP should be monitored time to time to ensure the
receiving of desired temperature range.

33. BAKING PROFILE
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Zone 8 Zone 9 Zone
10
Upper 220±20 240±20 260±20 280±20 290±20 300±20 275±20 245±20 240±20 220±20
Bottom 200±20 230±20 250±20 270±20 285±20 290±20 250±20 230±20 235±20 190±20

34. CHANGES DURING BAKING
 Evolution and expansion of gases
 Coagulation of gluten and gelatinization of starch
 Partial dehydration from evaporation of water
 Development of flavours
 Change of colour due to Mallard browning
between gluten protein with milk and reducing
sugars as well as other chemical change
 Crust formation from surface hydration
 Crust darkening from Mallard browning and
caramelized sugar

35. 6. COOLING
 The hot baked biscuits from oven are
conveyed through cooling conveying belt for
cooling of biscuits.
 The total travel of the cooling conveyor is 1.5
times of the oven length.
 It is done for 5-7 minutes so that biscuits
become cool and all the moisture gets
evaporated.
 A metal detector is placed after cooling to
avoid any metallic contamination.

36. 7. PACKAGING UNIT
 Sealing machine - It is used to seal poly pack of
biscuits.
 Taping machine - It is used to seal the cartons.
 Multipack machine - It is a fully computerized
machine to pack packets of different weights
according to requirements.
 Packaging material - Two types of materials are
generally used.
1. BOPP (Biaxially Oriented Polypropylene) films
as primary packing material.
2. Corrugated fibre boards as secondary packing
material.

37. 7. PACKAGING UNIT
(CONTD.)
 The conveyor continues to move to counting
table where biscuits are counted & then to
staking table at which biscuits are packed in very
orderly manner.
 From staking table, the biscuits are moved on
conveyor to multi pack wrapping machine.
 During sealing of packet, the temperature of upper
jaw and lower jaw is 140ºC.
 Parle-G are packed into poly bags & sent to
sealing machine where it is sealed, then to
corrugated box section where poly bags are
placed manually and box is passed through at a
taping machine where the boxes are tapped.

38. SEALING MACHINE TAPING
MACHINE

39. MULTIPACK MACHINE

40. CODING
 Coding includes PKD (month & year), Batch
number (PN i.e. Pantnagar, date, shift, B)
 Short date coding - Parle –G (70g)
 Long date coding - Parle-G (140g)
 Note - There should be same coding in box,
packet, coupon and poly bag.
 During offline coding the wrapper font size
coding should be of same height not less than
2 mm.

41. GENERAL DATA FOR PARLE-G
 Weight of baked biscuit = 5.5-5.10gm
 Number of biscuits in 1 packet (45gm) = 9
 Weight of baked biscuit + weight of packet =
46.45gm
 Length of biscuit = 55 mm
 Width of biscuit = 36mm
 Stack height = 105-107mm
 Baking time = 3.30 min

42. HACCP
 Stands for Hazard Analysis and Critical Control
Point.
 It is a systematic preventive approach to food
safety from biological, chemical, and physical
hazards in production processes.
 Critical Control Points
(1) Sugar syrup filter press
(2) Maida sifter sieves
(3) Metal detector – For ferrous =1.5mm
For non-ferrous=2.0mm
For S.S. = 2.5mm

43. GMP (GOOD MANUFACTURING
PRACTICES)
 GMP Is a production and testing practice to
ensure a quality product. It covers following
parts –
1. SOPs (Standard Operating Procedures) –
 Step by step procedures
 Product consistencey & safety
 Legal requirements

44. 2. Personnel – Behaviour & dress
 Smoking, eating & drinking are prohibited
 Aprons, hair covering, no jewellery
 Proper hand washing
3. Good Housekeeping
 Operational
 Storage area
 Administrative

45. CONCLUSIONS
 Practical part was seen i.e. from procurement of
raw material to the final dispatch.
 Proper process control and quality checks were
maintained.
 Protocols followed in the entire process.
 Allotment of responsibilities and authorities for
food safety and management system.

46. THANK YOU…