Biscuit production

1. PARLE
COMPANY PROFILE
The company ‘Parle-G Biscuits Pvt. Ltd’ set up in 1929, the first Indian company to
manufacture biscuits and confectionery in the country. Many of Parle products, biscuits and
confectionery are market leaders in their category. One of its major varieties, Parle-G has
been conferred with prestigious distinction of being the world largest selling biscuits. With a
40% share in the total biscuits market, a large number of manufacturing units in the industry,
the company enjoys a world class reputation and the ‘Parle’ brand symbolizes quality, health
and good taste for its products.
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.
WORKING STRUCTURE
5’S Policy
 Seiri- Reorganization
 Seiton -Neatness
 Seiso - Cleanliness
 Seiketshu - Standardisation
 Shitsuke – Discipline
HYGIENE
Area
Trimmed nails
Bath on daily basisOven End

2. INTRODUCTION ABOUT BISCUITS
Biscuits are chemically leavened and baked products made principally from flour, sugar and
fat. Their moisture content is less than 4% and can have a long shelf life when packed air
tight. They are ready to eat and are manufactured in attractive and appealing packing. They
are made in variety of shapes and sizes and after baking they may be coated with chocolate
and sugar or may be sandwiched with flavoured cream.
CLASSIFICATION OF BISCUITS
Depending on texture and hardness, change in shape of oven the extensibility of dough or
various dough is handled prior to biscuit formation:
 Hard dough biscuit: It has high water and relatively low fat content. The dough is tough
and extensible. They exhibit viscoelastic properties similar to bread dough because of the
three dimensional gluten network of flour protein.
 Soft dough biscuit: They contain much less water and relatively high level of fat and
sugar. Soft dough coheres under pressure but has a short fracture under tension and very
little dough development takes place during mixing.
Depending on relative amount of sugar and fat used the biscuits may be classified as follows:
 Sweet biscuits: With more fat and more sugar.e.g.glucose biscuits
 Semi sweet biscuits: Have less fat and sugar.e.g.Marie
 Salty biscuits: Have more fat and less sugar.e.g.Krackjack
General
GMP Zone
Brush teeth on daily basis
Wear clean uniform
No smoking and chewing
of paan, gutkha, tobacco
If you are suffering from
cold and cough don't enter
into the process area or
shake hand with the
working person
Wear cap and apron
Don't use strong smelling
perfumes and oil
Don't leave unwanted
debris
Maida sugar area
Sugar dumping area
Packing Section

3. GLUCOSE BISCUITS
These biscuits contain relatively more fat and sugar content and fall under the category of
sweet biscuits. The sugar used is mainly in the form of glucose and that is why these are
glucose biscuits. They form healthy diet and a good source of energy and are economically
cheaper than other variety of biscuits. A majority around 65% of the total biscuits
manufactured in India are glucose biscuits.
INVENTORY
Inventory management is primarily about specifying the size and placement of stocked
goods. Inventory management is required at different locations within a facility or
within multiple locations of a supply network to protect the regular and planned course
of production against the random disturbance of running out of materials or goods. The
scope of inventory management also concerns the fine lines between replenishment lead time,
carrying costs of inventory, asset management, inventory forecasting, inventory valuation,
inventory visibility, future inventory price forecasting, physical inventory, available physical
space for inventory, quality management, replenishment, returns and defective goods and
demand forecasting and also by replenishment or can be defined as the left out stock of any
item used in an organization.
INVENTORY CONTROL TECHNIQUES
Inventory control is also about knowing where all your stock is and ensuring everything
is accounted for at any given time.
 Ensuring that the products are on the shelf in shops in just the right quantity.
 Recognizing when a customer has bought a product.
 Automatically signalling when more products need to be put on the shelf from the
stockroom.
 Automatically reordering stock at the appropriate time from the main warehouse.
 Automatically producing management information reports that could be used both by
local managers and at head office.
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 area.

4.  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
RAW MATERIALS
S.No Commodity Maximum
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
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
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

5. maida
 Sugar – It is a valuable source of flavour in biscuit and is responsible for structure and
hardness in short dough biscuits. Apart from that, it aids surface coloration during
baking. It also acts as an enzyme carrier.
 Invert syrup- Sucrose sugar is hydrolyzed by acids/enzymes into two monosaccharides –
glucose and fructose. This reaction is known as inversion of sugar and the hydrolyzed
mixture is known as invert syrup. It prevents surface crystallization and is resistant to
microbial spoilage because of lower water activity. It gives colour and helps in moisture
retention.
 Salt – Salt modifies other flavours, enhances sweetness of sugar and decreases sourness
of acids. It affects the rheology of dough and improves the dough crumb colour.
Increasing salt increases mixing time.
 Water – It acts as solvent to form dough when mixed with flour. The water is allowed to
steam which acts as a leavening agent and helps in expansion.
 Skimmed milk powder (SMP) - It is obtained by spray drying of fatless milk. It provides
nutrients to product and gives the liquid media for dough formation, used as a
minor dough ingredient to give subtle flavour and textural improvements to aid
surface cooling.
 Ammonium bicarbonate (ABC)- It is used as a leavening agent .It decompose
completely when heated, giving carbon dioxide , ammonia gas and thus leaving no
residue in baked biscuits. It is used to maintain the stack height of biscuits.
 Sodium bicarbonate- It is a self contained leavening agent and is used as a means of
adjusting the acidity of dough and taste of biscuit. If its granules remain undisclosed in
dough, they may decompose to carbonates, which can give undesirable alkaline flavour
and a yellowish crumb. It has puffing activity.
 Sodium meta bisulphate (SMBS) - It is used in very small quantities as a preservative
and to modify gluten quality chemically. It cases the gluten to become more extensible
and less elastic and therefore reduces the shrinkage of dough pieces as they are baked.
 Lecithin- It acts as an emulsifier and permits the easier dispersion and blending of fat in
the dough and it gives possibility of reduced fat usage to obtain similar textural
properties.
 Finamul- It also acts as an emulsifier and functions largely in same way as lecithin, the
only difference being that it is soluble in water while the lecithin is fat soluble.
 Vanilla flavour- It is an artificial flavour added to induce the characteristics flavour into
the biscuits. It has added natural colour, is non fruit based and alcohol free.
 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-It is mixed with Parle flavour in PFM tank to make flavour.
GENERAL STEPS IN GLUCOSE BISCUITS MANUFACTURE
 Handling and metering of ingredients

6.  Mixing of ingredients
 Rotary moulding
 Baking
 Cooling
 Packaging
 Storage and distribution
PROCESS LAYOUT OF PARLE BISCUITS
All plants of Parle Biscuits Pvt.Ltd. buy raw materials from the various suppliers and store
them into store room. These raw materials are then sent to laboratory for testing and after
testing only then these are used for manufacturing Parle-G biscuits.
For the production of Parle-G biscuits the whole plant consists of different units to perform
various works. Parle-G biscuits plant is divided into different sections, they are as follows-
 Raw material storage
 Maida sugar section
 Mixing unit
 Rotary unit
 Oven
 Packaging unit
RAW MATERIAL STORAGE
Each industrial plant should have an area for raw material storage. In these storage areas, the
raw materials are kept until they are used for the production of desired finished product. For
the production of Parle-G biscuits, a variety of raw materials are required such as Maida,
Sugar, Sugar Syrup, Vanaspati, etc.
MAIDA SUGAR SECTION
Both maida and sugar are stored in large vertical tank. RBD is stored in vertical silo.
These storage areas should be free from moisture, water logging, direct sun light, insects, and
rodents, so as to keep the material safe before it is used.
MIXING UNIT
In the production of biscuits this Mixing unit is most important part of total production area.
This unit consists of various vessels or mixers to perform mixing work in a measurable way
for different ingredients used in biscuits production-
 Powder vessel- Powder vessel receives Maida from Maida Service tank through
pipelines. This vessel receives 110kg of Maida per batch.

7.  Creamer vessel-It receives ingredients such as Ghee, Powdered sugar, skim milk,
Palm oil from RBD through pipeline at temperature 40-45°C. Powdered sugar is
passed through vessel or service tank and SMP is provided to the creamer vessel.
Finamul is used as emulsifier mixed with Palm oil. In 800kg of Palm oil, 2.490kg
finamul is mixed. Finamul is directly supplied through pipeline with Palm oil to the
creamer vessel.CV agitator is attached to the vessel to agitate the ingredients
properly.
 Liquid vessel- It receives 300gmSoda,650gm Salt, 1200gm Ammonia, Sugar Syrup,
PFM (Parle flavour mix) ,and water. 2.5kg of SSA is provided to vessel. About 11kg
of sugar syrup and11kg of water is supplied to the vessel through pipelines. Only 190 ml
of PFM is used in a single batch. Temperature of sugar syrup should be about 42°C
and for water temperature should be 2.6 during summer time. Colour of sugar syrup is
golden brown. pH is about 2.9.LV Agitator is attached to vessel to agitate the ingredients
properly. Ammonia is used for puffing of biscuit during baking and maintains stack
height of biscuits. If the amount of ammonia is more than the stack height will increase
and vice versa. For reprocessed biscuit another machine is fixed makes RB paste that
mixed in dough with 7 kg per batch.
 Stephen Mixer- The Stephen TK Mixer is an ideal component to fully automatically
feed the downstream make up equipment for biscuits. Stephen mixer is powerful and
versatile. Automatic make up equipment is fed totally automatically by the Stephen
mixer. There are two types of motor attach to mix all material properly .They are
Baffle motor and Mixer motor. Rotation in Stephen mixer is about 600 to700
revolutions. The operation divided into four phases: loading, mixing, kneading and
discharging. After loading the mixer with all ingredients, the mixing starts. The unique
shape of the mixing/kneading tool, combined with the mixing baffle, produces a very
homogenous mix. The combination of the mixing tool allows for the optimum hydration
of the flour. Due to this intensive hydration, a higher yield is possible in the range of 1.5-
3% depending on the type of dough. This complete development leads to a delicate
crumb and an extremely machine able dough. Using a special attachment, the Stephen
Mixer can knead the dough’s under a vacuum, if it is desired to have a super fine pore
structure like American or English white pan bread.
ROTARY UNIT
It has rotary blades to rotates and mix it finally as the final dough is formed.Dough
temperature is about 33.5°C. Roller rolls the dough and cutting knife help in cutting the
dough in spreaded from so that dough should pass from roller die equivalently and each
cup of die receives appropriate amount of dough to form biscuits. Rubber roll provides a
pressure to dough of 2.5kg for better shape of biscuits in die. Rubber lined anvil roller is
adjustable in height so that pressure can be controlled at both sides in parallel or
independently. The anvil roll is being driven by friction of the cutting web, which is
independently powdered by its own separate drive. For safety reasons the cutting roll is
provided with guard, removal of which stops the motor. Roller Die drum has 12 cups in
circle and 31 cups in length of the die drum. Die give the shape and size to biscuits and

8. also imprint the name of product on biscuit i.e.Parle-G on the top of biscuits. After this
biscuits are passed on to rotary belt. Then the biscuits are conveyed up to oven and
these biscuits are passed on the wire band belt fin oven.
OVEN
The oven used for baking is divided into various zones according to temperature employed.
Number of zones that are required are based upon rpm used. The oven body consist of steel
steam tight tunnel with equally divided zones of the radiators. Stainless steel expansion joints
are provided between these zones in order to eliminate the expansion of the oven section. The
inspection doors are provided for inspection of the baking goods during the process. Propane
gas is used as fuel. Width of the oven is 54.5 inches and its length is 728 ft. During
starting process moisture content of biscuit is used. After that 4-5 zones biscuit gets enlarged
due to leaving of carbon dioxide and ammonia. It continues till 7-8 zones.
Last few zones are colour imparting zones. During this, colour of biscuit changes from white
to brown. This colour change is because of Mailard browning reaction. Source of heat used in
oven is propane. Propane is injected along with air under high pressure to produce heat. Total
length of oven is divided in three zones i.e. first 30% length of oven is known as puffing
zone, middle 40% length of oven is known as baking zone and last 30% length is known
as colouring zone. Temperature in the oven is in parabolic range during starting. During
starting and end zones temperature will be less and in middle four zones, the temperature will
be high upto 320±20ºC.
There are damper plates at each zone of oven whose opening and closing maintain the
steam inside the oven. During first three zones damper plates are 20% to 30% open, so
as to maintain the steam in oven for better puffing of biscuits. In zones number 4, 5, 6 &
7, the damper plate is open about 40% to 60%. At this level, the biscuits are baked and
temperature of these is also high. And last three zones i.e.8, 9 &10, the damper plates is
almost totally opened to release all steam from the oven.
Zones number 6, 7&8 are known as CCP zone. Minimum temperature of CCP zone is
230ºC to 320ºC. These zones help in controlling the moisture of biscuits and also increase
the shelf life of the finished product. This CCP zone 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 that this zone is receiving the desired temperature range or not. When
biscuits are fully baked at the tenth zone they are released on the cooling conveying belt for
better cooling of hot baked biscuit. Colour of fully baked biscuit is golden brown. Standard
baking time is 3min.30 sec.
At rpm of 32:
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

9. Bottom 200±20 230±20 250±20 270±20 285±20 290±20 250±20 230±20 235±20 190±20
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 Mailard browning between gluten protein with milk and
reducing sugars as well as other chemical change
 Crust formation from surface hydration
 Crust darkening from Mailard browning and caramelization of sugar
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. The biscuit continues to run on it for 5-7 minutes so that the biscuits become
cool and all the moisture that biscuits contain gets evaporated. A metal detector is
placed after cooling when biscuits move towards packing so as to ensure that the biscuit
is free from any metallic contamination.
PACKAGING UNIT
This is fully automatic plant consisting of sealing machine, taping machine and multi pack
machine.
 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- There are two materials which are generally used. BOPP films are
used. BOPP stands for biaxially oriented polypropylene. Corrugated fibre boards are
used as a secondary packing material.
The conveyor continues to move to counting table where biscuits are counted and seen
that it is going properly or not. The conveyor continues till the biscuits reach the staking
table at which biscuits are packed in very orderly manner.
From cooling conveyor some biscuits are diverted through auto feeding machine to another
staking machine where packing is done. This auto feeder has inline pusher and cross pusher.
Cross pusher maintain the counting of biscuits. Stack height of biscuits is also checked at this
level. Auto feeder machine has a control panel to control cross pusher. From staking table,
the biscuits are moved on conveyor to multi pack wrapping machine. During sealing of

10. packet, the temperature of upper jaw and lower jaw is 140ºC. There are two roller sealers
for bottom sealing. When the biscuits are packed in plastic wrapper, these packets are
conveyed in forward direction. Then a certain number of packets of Parle-G are packed
into polybags. And after packing it into polybags, it is sent to sealing machine where it is
sealed, then it is sent to corrugated box section in which a certain number of polybags
are placed manually and box is passed through at a taping machine where the boxes are
tapped. Then these are sent through a long diversion conveyor belt. This belt helps to
transfer the box to dispatch section directly.
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. While offline
coding the wrapper font size coding should be of same height not less than 2 mm.
HACCP
It 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 that can cause the finished product to be unsafe, and designs measurements to
reduce these risks to a safe level. ISO 22000 is like a standard designed to help augment
HACCP on issues related to food safety. Although several companies, especially big ones,
have either implemented or are on the point of implementing ISO 22000, there are many
others which are hesitant to do so.
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
MISCELLANEOUS
REASONS FOR INCREASE IN STACK HEIGHT
 Dough quality
1. Quantity of ghee is less.

11. 2. Quantity of sugar is more.
3. Dough temperature is more.
4. Increase in amount of ammonia.
 Molding
1. More weight of biscuit.
2. Pressure due to roller is less.
 Baking
1. Damper position
2. Proofing zone has high temperature.
REASONS FOR INCREASE IN LENGTH OF BISCUIT
 Dough quality
1. Moisture content of dough is less.
2. Amount of sugar is less.
3. Amount of ghee is less.
4. Mixing time is more.
5. Reprocess able dough is more.
 Baking
1. Distance between two biscuits is more on wire band.
 Rotary
1. Speed of rubber roll is more.
2. Standing time at proofing zone is more.
REASONS FOR INCREASE IN WIDTH OF BISCUITS
 Dough quality
1. Consistency of dough is not proper.
2. Amount of ghee is more.
3. Amount of sugar is more.
4. Particle size of sugar is small.
5. Particle size of Maida is small.
 Mixing
1. Mixing time is less.
2. Improper temperature of dough.
 Baking
1. Bottom temperature is less.
2. Mostly damper plates are closed.
3. Temperature of first zone is less.
 Molding
1. Weight of biscuits is more.
2. Excessive pressure of rubber roll.

12. FACTORS AFFECTING PROCESSING OF BISCUITS
 The major factor governing the eating characteristics of glucose biscuits is the
consistency of dough formed as a result of mixing. The nature of viscoelastic properties
of dough mainly governs the texture, spread, colour and bite of the resulting biscuits. This
depends upon nature of the flour, and its gluten forming characteristics. More extensible
or less elastic dough is desired during biscuit manufacturing.
 Sometimes improper mixing of fat and water in the batch results in excess gluten
formation as the flour is more in contact of water. This causes the dough to become less
extensible or more elastic leading to improper spread and texture of the biscuit. This can
be overcome by creaming of fat using emulsifier and then mixing with water so that it
forms a good emulsion or both. This causes the dispersion of fat evenly throughout the
dough and limits the formation of gluten.
 Sugars depending upon the level and type affect the rheological characteristics of the
dough. Increasing the sugar content reduces the extrusion time, dough consistency,
biaxial extensional viscosity and increases the spread. Development of gluten is also
reduced and there is an improvement in the texture of biscuits.
 Incorporation of additional reducing sugar, particularly liquid glucose and syrup limits
gluten formation and produces changes the adhesiveness and stickiness of the dough.
 The mixing time as well as the standing time of the dough also affects its characteristics.
If the dough after mixing is allowed to stand for a longer period, gluten formation
enhances and the dough becomes harder.
 The content of leavening agent in the dough as well as condition of temperature and
pressure inside the oven influence the baking characteristics to a great extent. Biscuits
baked under reduced pressure than normal have better textural profiles.
 The control of moisture in the biscuit is critical to insure its greater shelf life and
microbiological safety as spoilage accelerates in presence of high moisture content. As
soon as the biscuit cools, it must be packed in minimum possible time so that it does not
absorb moisture from the surrounding atmosphere.
 Emulsification improves the ability of the protein film to entrap air in the batter during
creaming or mixing. The biscuit made by using emulsifier have more crispness.
 Colour of biscuits is due to Mallard reaction and caramelization of sugar.
 Time requires to bake the biscuits in oven is generally 3-4min. Baking time depend on
rpm of die and rotary. Higher the rpm, lower will be the baking time and vice-versa.