Presentation on Training in CMU

Presented by: Kuldeep Wadhwa In-plant trainee (Biscuits), Tahliwal (H.P)

Introduction to CMU

Foundation of CMU was laid by Mrs. Rajni Bector. ITC started its collaboration with CMU in Oct 2004. Currently it is monitored/governed by Mr. Anup Bector. Plant Specialty : 2 lines of ITC & 2 lines of Cremica are running parallel .

ITC Structure at CMU

ITC Staff

Team Leader

3 M.E.

1F.E.

CMU Structure
Plant Manager Production Mngr Quality Mngr

Shift Incharge (SI)

Supervisor(Sup) Operator(Op)

SI
Sup Op

SI
Sup Op

Packaging Incharge

Workers

Plant Capacity
Total capacity :104 Ton/day, which comprises of : a. Cream : 53 ton b. Cookies : 51 ton.

STD. Consumptions
Fuel Consumption: Cream Line : 50 liter/ton Cookies Line : 41 Liter/ton Electrical Energy Consumption : Contract Demand : 900 KVA Cream Line : 120 unit/ton Cookies Line : 91unit/ton

Overview of the Plant

Premixing Area Level-4 Mixing Area Level-3 Moulding , Baking & Packing of Cookies line Level-2 Sandwiching &Packing of Cream line Level-1

RM/PM Flow
Material entry at gate Sampling OK Lab decision Bill to stores Weighment Stores to inform Lab , entry in Lab Register Lab- check all QA reports, inform to stores Stores- prepare GRN, Give receipt Submit Bill, GRN to ITC & Maintain one copy of GRN in File

Inform to stores
Not Ok Reject the material , inform ITC Stores- Send the material Back to supplier

Process flow diagram for Biscuit Mfg.

Raw material procurement & testing Premixing (Grinding, Sieving & weighing) Mixing (Dry Creaming ,Wet creaming & Mixing) Forming (Rotary Moulder) Baking Stacker Packing & Packaging Product Quality Inspection Dispatch Cooling Conveyors Metal Detector

Flow Chart of Receiving Fuel in Burners

Tanker

Main Tank (35000lit, 50C,1 kg/sq.cm)

Buffer Tank (1000 Lit, 55-60C)

Day Tank (2000lit, 80-90C)

Ring Main(8090C, 2.5kg/sq.cm)

Main Line(8090C) Burner

Pre-Mixing Floor (Level-4)

1. 1. 2. 3. 1. 2. 3. Line-1 is for cream & Line-2 is for cookies. Line 2 has 1 creamer & mixer , whereas Line 1 has 2 mixers. There are 4 ingredient hopper, 2 of each line (L-2 & L-3) Broken Dust Room Sieve Shifter 16# is used for both lines. Chemical Room Sieve Shifter 30# (SMP,SODA,SAPP) Sieve Shifter 16# (SALT & ABC) Sieve Shifter 30#(STARCH & ELACHI) Storage Room of Raw Materials Intermediates Blend preparation Two Invert syrup preparation tank & 5 storage tank. Black jack preparation & storage tank (Both 2 in no.) 2 storage tank of Palm oil.

Mixing (Level-3)

4 mixer , 2 of each line 1. Line-2 for Creams 2. Line-3 for Cookies Sugar Grinding & Maida Shifter Dough dozing hopper & feeding roller. 2 Metal Detector

Rotary Moulder Area(Level-2)

Moulding & Forming Ovens Cooling conveyors 1 Metal Detectors at Pre-stacker of Cookie line Multi Pack Packing M/c DH Room CFC Packing M/c of Cookies line

Packing Area (Level-1)

DH Room (Humidity =<45%) Cream Preparation Room (Mirinda & Ganson System) Cooling Conveyor for Shell 1 Metal Detector at Pre-Stacker Area Peters M/C ( PT2, PT4) & 4 ABM CFC Taping M/C Finished Goods, Packing Material Store. Sugar Grinding Room

ITC Standards for Ingredients

Raw Material: Maida

Parameter Appearance ITC Specification White-creamy white. On sieving-free from any rodents etc. Free from any musty Flavor/ Odour. <=14% >=22ml =<.65% Significance To check Maida is infest free & fresh To ensure absence of off taste/smell High m/c-low shell life & low yield It tells about the quality of gluten in the dough It indicates the total mineral contamination

Taste & Smell Moisture Sedimentation Value Total Ash

Raw Material: Sugar

Parameter Moisture ITC Specification <.08% by mass Significance/Reason Affects shell life & induce Caking leading to grinding problems Bleaching residue. Harmful to health Impurity Check Measure of inversion purity of Sugar Sulphur Content, affects taste Purity Check

Sulphated Ash Water insoluble impurities Reducing Sugar S02 Sucrose

.03% <.1%(DB) <.1% <70ppm >98%

Raw Material - HVO

Parameter Moisture & Volatile Matter Melting Point FFA Content Per Oxide Value Iodine Value ITC Specification <=0.1 33-39C <=.07% <=1.5meq/kg 69-75 Summer 71-76 Winter 184-198 (ml of NaOH required to completely neutralize the material) Significance/Reason Moisture Content Basic property of the fat Total free fats (more prone to rancidity) Indicative of oxidative rancidity Indicates degree of instauration & hence Shell life Everything apart from fat(FFA, alkaline impurities) which can form soap in alkaline medium. Determines adulteration with other fats. Measure of extraneous value

Saponification Value

Unsaponification matter

<=1%

In Process checks
Location Premix section Post-Mixing Pre-baking Parameter Invert Syrup: pH, Premixing Chart Dough Consistency, Hand Feel Wet weight, impression, appearance Frequency Each batch Each batch 15 Mins

Baking
Post baking

Stack, Color , Shape

Dry weight, stack, Biscuit Dimensions, Moisture %.

15 mins
20 mins

Role of Ingredients
Maida : It gives the basic texture & strength to the biscuit Sugar : It gives Sweetness to the Biscuit as well as acts as structural & flavor Modifier. Oils & Fats: To give pastry a crumble texture. Invert Syrup : Acts as humectants as well as adds sweetness. Lecithin, Finamul-90 : acts as Emulsifiers. Sodium bi-carbonate: acts as leaving agent, used to increase the volume & lighten the texture.(Puffing action). Sodium Acid pyrophosphate(SAPP):delays the reaction time of SBC which helps to get a desired puffing texture. Ammonium bi-Carbonate: It acts as a leavening agent. Salt: Flavor enhancing , toughens dough Sodium meta bisulphate(SMBS): it is used to modify the quality of gluten. It causes the gluten to become more extensible & less elastic. Reduces the Shrinkage of dough piece during baking.

Ovens

Indirect heating ovens are used. Line 2- 6burners (225 ft) Line 3- 7 burners (250 ft) Zone 1- Moisture removing Zone 2- Development of structure Zone 3-Puffing Zon4- Puffing Zone 5- loss of moisture from biscuit Zone 6- Colour changes Zone 7-Prominent colour change

Packaging of Biscuit
In CMU biscuits manufactured by Multi Pack, Peters & ABM M/c are

packed into following packing's as follows :

Primary packing/ Laminate Secondary packing Tertiary Packing

Defects in Packing
Packing Defect
White Line

Reason
1. Presence of half cut biscuit in In-line feed . 2. During laminate change over. 3. Due to mismatch of laminate position in laminate roller. 4. During when M/c is turned off. 1. Due to tailing in biscuits 2. Due to presence of Broken biscuits in Inline feed. 3. Due to improper setting of form box. 4. Due to excess heat of Jaws etc. 1. Improper sensing of photo cell. 1. Low quality of laminate 2. Improper seal of roller setting. 3. Excessive heating 1. Improper code size or its wear & tear.

Puncture

Out Packet
Wrinkle

Miscoding

End seal joint

1. When broken biscuit is entrapped in the packet. 2. Excess Cream Layer is coming out.

Associated Machinery & Equipments

Power Supply: 3 phase power supply (415-430V, 50 Hz ) & Single phase (220-240V, 50 Hz ), SMPS for PLC. Generator s : 3 Generators of Capacity as follows 500 KVA, 380 KVA , 380 KVA. Transformer : 1250 KVA Controllers : PID Controllers. LT Panels for controlling purposes METAL DETECTORS: 4 in number , used 2 each at dough & stacker level respectively Minimum Detectable Quantity : 2050 mV ( Pre-stacker of cookies line).

Effluent Treatment Plant

Need : In order to get approval for running the industry ETP Setting up is required . Secondly It is basically done to determine Environment impact assessment Aim : To bring back again quality of impure water up to that level that it does not harm aquatic life. Quality standard of treated water: pH : 5.5-8.5 COD : 250 mgpl (max) BOD : 30 mgpl (max)

Quality Tests (lab)

Packaging: Laminate:
1) 2) 3) Dimensions Texture Printing matter

1. 2. 3. 4.

Poly bags:
Dimensions Hole puncture Yield Perimeter of formed bag

CFC :
Dimensions Bursting strength Flap bend & Flap gap (<= 5mm) Printing colour & Scheme

Finished goods (FG)

Moisture Content Ash Content Acid in Soluble Ash Acidity of Extracted fat Fat Content

Legal Compliances, Licenses & Agreement

Various Licenses are to taken before setting up of plant . Important ones are as follows: Effective utilization of electricity i.e. approximate unity power factor running satisfaction has to be provided. Environment impact assessment Certification has to be obtained from pollution board . Legal compliances : Food safety standard authority of India formerly known as Prevention of food Adulteration Act , 1954. (Center Certification) Legal Meteorology formerly known as Weight measurement( State Authority certification). Agreements: are set between CMU & ITC depending upon various types of conditions.

Production Plans
Factors considered while making Production Plan :
Plant Capacity Working days M/c Ratio M/c Capacity Variety Cycle Availability of stock