HIERARCHY OF PARLE PRODUCTS

CHAIRPERSON

EXECUTIVE DIRECTOR

PRODUCTION MANAGER

PRODUCTIONMANAGER

BISCUIT

CONFECTIONERY

CHIEF ENGINEER HRD BISCUIT MANAGER PERSONEL ADMINISTRATOR EMPLOYES

ENGINEER OFFICER

CONFECTIONERY

PRINTING

SUPERVISORS CHARGE HAND EMPLOYEE

MANUFACTURING PROCESS FLOW CHART

RAW MATERIAL TESTING

MIXING

MOULDING

BAKING

COOLING

PACKING

PROCESS LAYOUT
STEPHAN MIXER STEPHAN MIXER

MOULDING

OVEN

CURVE PLATE

COOLING CONVYER CURVE PLATE

STALKING TABLE

MULTIPACK MACHINE

BOX TAPPING DEVIRSION BELT CONVEYOR BELT

SEALING MACHINE

CONVEYOR BELT

DISPATCH SECTOIN

PROCESS LAYOUT OF PARLE PRODUCTS LTD.

PARLE G are made at parle products ltd. at vile parle . First of all the parle products buys RAW MATERIAL from the various suppliers and stored into the store room. This raw material is then sent to laboratory for testing and after testing only it is used for manufacturing. The raw material consist of Wheat flour, Sugar, Partially hydrogenated edible vegetable oils, Invert syrup, Leavening agents (503 Baking powder) Milk, solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough conditioners (E 223). Such a mixture of raw material is taken and mixed into STEPHAN MIXTURE, which is high power mixture machine. Specially made for mixture of dough, from which the mixture is passed to molder called ROTARY MOULDER. Through that moulder approximately 10,000 come out in a minute. Moulder had 260 cups fitted in it which gives shape to the biscuits and an impression embossed on it of parle-g. From rotary moulder the dough is passed through a 260 feet long OVEN which is approximately 340* c. In oven there are three stages to be followed Removal of moisture. Building the structure of biscuits. Colourings of biscuits take place.

From oven the hot biscuits are placed on the COOLING CONVYOR, which is 260 feet long and the biscuits continues to run on it for 5 to 7 minutes so that the biscuits become cool and all the moisture that biscuits contain gets evaporated. And because of the above reason the factory has S FLOW LAYOUT in the factory. The conveyor continues to move to COUNTING UNIT where biscuits are counted and seen that it is going on properly or not. The conveyor continues till the biscuits reach the STALKING TABLE at which the biscuits are packed in very orderly manner.

From cooling conveyor sum biscuits are diverted through AUTO FEEDING MACHINE to another stalking machine where packing is done. From stalking table the biscuits are moved on conveyor to MULTI PACK WRAPPING MACHINE were 16 biscuits are packed into a regular parle g wrapper so that the weight of 16 biscuits comes up to 100 grams. Then 24 packets of parle g biscuits are packed into a POLY BAG And after packing it into poly bag it is sent to SEALING MACHINE where it is sealed, Then it is sent to CORRUGATE BOX SECTION in which 6 poly bags are placed and Then the boxes are kept on conveyor and sent to DISPATCH SECTION from were the biscuits are sent to various places in India and all over the world.

RAW MATERIAL Wheat flour Sugar Partially hydrogenated edible vegetable oils Invert syrup Leavening agents (503 Baking powder) Milk solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough conditioners (E 223) and contains added flavours. The raw material is mixed in certain proportion, to get the best quality of biscuits. All the ingredients are tested in laboratory so that no low quality of raw material is used in manufacturing process. The raw material is tested for their acidic value, moisture it contains, and quality of milk powder.

INVENTORY The inventory of the company that is the raw material is of a week. They store such inventory in store room and then is sent for testing in laboratory and after testing it is sent for production.

SHIFTS There is nearly 10,000 employees working in the company and are working in three shifts.35,000 tones of biscuits are manufactured in a day of one particular product, and there are such nine product manufactured in the factory.

WASTAGES There are two type of wastage in factory. First is the waste materials fallen on ground. Such waste material is of 1% which is marginal and acceptable which goes into total waste. Second types of waste are the biscuit collected in tray of the multi-pack wrapping machine, since these biscuit are broken they are not packed and sold to the customer but collected in other tray and sold as broken pieces and sold for less price for cattle feeding.

LOOSE BISCUIT On the stalking table one to two rows of baked biscuits are kept aside for selling it as loose biscuits. They are normally assumed to be damaged biscuits but they are not damaged or broken but company keep such loose packets of biscuits to sell it to the local people for marginal rate of 33 Rs / kg.

FOLLWING ARE THE MACHINERY USED IN MANUFACTURING STEPHEN MIXER The Stephan TK Mixer is an ideal component to fully automatically feed the downstream make-up equipment for biscuits, bread, rolls, buns, cake, sweet goods, cookies and crackers. The advantages are compelling: High volume output results from the short kneading time and fast ingredient charging: 1000 kg/h to 6000 kg/h depending on the model. Totally unassisted automatic discharge combines with predividing of the dough into approximately 15 kg. Pieces, is the basis for a fully automatic operation without the need for any full-time operator. Dosing of flour, water, yeast, salt, shortening and other nutrients. In a few seconds, all ingredients are homogeneously mixed. Then, as the dough begins to develop, the Stephan energy meter control will ensure each dough is finished to the same development The Stephan Mixer is most economical with: No-time dough formula Straight dough Liquid broth (yeast slurry) system Flour fermented liquid sponge system. From batch to batch, the doughs will be consistently uniform: "Process Control" Compact construction, no building preparation necessary, almost service-free day-today operation. The direct drive design allows the kneading element to be fastened directly onto motor shaft. There is no coupling or power transmission. Easy to clean. Only solid stainless steel construction. Quiet operation, less vibration.

Count on a better result. In these competitive times, good kneading is not enough. For a profitable operation, you need a short process time and an exact control on input energy which allows you to mix each dough to the same development curve. A short amortization of the capital investment occurs due to an increase in productivity more finished product from same amount of flour - and due to a perception of better quality in the areas of longer shelf life, "a delicate crumb", softer crumb structure, higher volume and increased flavor. The process control is simple and reliable. The processes of ingredient loading, mixing and dough discharge are controlled by each program. Depending on the ingredient loading system design, the recipe change needs no change of program. However, if the dosing system can not be adjusted independently, then a different program can be used for each recipe. The ingredient loading system should be designed to allow each scaled ingredient to be weighed during the mixing time of each previous batch. With this prescaling or staging of ingredients, all ingredients are ready to be charged at the same time. This system design will save time and thereby increase output. This control system would operate the entire loading, batching, mixing, discharging and dough conveying system. This would include the logic for accurate scaling of ingredients. Here's how the Stephan Mixer works. The operation can be divided into four phases: loading, mixing, kneading and discharging. After loading the mixer with all ingredients, the mixing process starts. The unique shape of the mixing/kneading tool, combined with the mixing baffle, produces a very homogeneous 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 Stephan Mixer can knead the doughs under a vacuum, if it is desired to have a super fine pore structure like American or English white pan bread. Stephan Mixers are powerful and versatile. Automatic make-up equipment is fed totally automatically by the Stephan Mixer. Quality improvement and automatic batching are the main advantages of the Stephan Mixer. Biscuits and rolls will have bigger volumes, more uniform texture and a more tender and delicate crumb. The Stephan Mixer is also used efficiently in the cookie and cracker industry for products such as:

Biscuits Bread sticks Soda crackers Rotary cookies Wire-cut cookies With only two different mixing and kneading tools, all of the above described products can be produced. STEPHAN MIXER

ROTARY MOULD

COOLING CONVEYOR

ROTARY MOULD

structure in corrosion-proof; anodised aluminum and Aisi 304 stainless steel satin stainless steel panelling swivel wheels and support feet trays loader with automatic chain feed feeder roller anodised aluminium presser roller in White rubber bronze moulder roller with quick change system scraper blade in stainless steel pressure adjustment of rubber roller on moulder roller scraper blade adjustment closed ring outlet belt with tension and centering adjustment belt cleaner blade with extractable drawer product outlet with power driven roller 1.00 kW speed variator

COOLING CONVEYOR The biscuit coming from stripping conveyor is directed on to the cooling conveyor to transfer the heat in the biscuit to atmospheric air as it is passing on it. The total travel of the cooling conveyor is 1.5 times the oven length. As per need specifications it need the travel of 150 ft. for effecting cooling. Cooling conveyor is made in a modular construction of 2.5 Meters. long and connected together to form the required length. The supporting side channels are fabricated from 3mm thick M.S. sheet. Idle rollers are spaced at 750mm apart on conveying direction and 1700mm on the return direction. All the idle rollers are of 48mm dia, mounted on 6004 ZZ deep groove ball bearings with grinding finish and hard chrome plated for hygienic conditions. During the production practically about the droppings of oil from the cloth due to rubbing of cloth against tie angles when producing high fat biscuits. To minimise this is replaced the all tie angles also with idle rollers. This might costs little extra, but you can maintain hygienic conditions at working area.

Drive drums are two no's. of 220mm dia and projections are made on the surface of drums to minimize slip or covered with friction grip rubber tape. Manual tensioning and tracking are provided. You can rely only on feeder table to stack the oil sprayed biscuits which does not require more travel after oil spraying.

LAMINATOR Laminators are generally used for production of all kinds of hard biscuits, crackers and cocktail snacks. With laminator it is possible to create a puffy pastry-like structure, which is of decisive importance for the quality level and consequently for the sales success. Laminating of Dough band improves the weight/volume ratio considerably i.e., quantity increase at same weight. In this superior functioning machine the dough band received from sheeter of 838mm width is passed through two shuttles. The dough sheet is cut into pieces by a knife for a length of 1000mm (39") and these pieces are laid on bottom shuttle by top shuttle. This bottom shuttle layers the pieces on first conveyor unit of 1000mm (39") wide production line very carefully. The first conveyor unit feeds to the first gauge roll unit. No. of layers can be controlled by the speed of first conveyor unit or increasing the speed of sheeting unit and laminator by A.C. variable frequency drive.

BISCUIT BAKING OVEN Construction: The oven body consists 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. And it is 260 feet long. Firing Chambers: The complete chamber are insulated with minerwoll filled from outside to conserve heat and increase efficiency. The fully automatic imported burner shall be fitted to the chamber and the temperature shall be controlled by automatic temperature controller on the control panel.

Insulation: The complete oven will be covered with 10" thick mineral wool insulation from top, bottom and the sides. The bottom portion of the oven at the sides will be covered with CRC sheets for the conveyor protection and to avoid heat loss. Baking System: The baking in the heating chamber takes place by radiators located under and above the wire mesh band which distribute heat for uniform baking. The recirculation heating gases of these radiators can be controlled for each zone separately. The closed recirculation system is having slight vacuum so that combustion gases can not enter into the baking chamber. The ventilating fan is for circulation of the heating gases through the recirculation system and thermostatically controlled burners provide the set temperature of the heating gases. Fans: All the circulating fans are fabricated from M.S. & S.S. and will be well balanced to avoid vibration and will give noise free operation in high speeds

ROTARY CUTTER The single head rotary cutter prints fine design on a continuously fed dough sheet and also cuts out the individual dough piece. The unit powered by 1.5KW helical geared motor and speed controlled by AC frequency controller. Drive is given to cutting roller only to accommodate different sizes of die's in this machine. 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 powered by its own separate drive. For safety reasons the cutting roll is provided with guard, removal of which stops the motor.

COUNTING UNIT The counting unit counts and see that the biscuit making process is going fine or not, i.e. as per the program set in the machine, program is set as per the grams required. Generally 16 biscuits are taken by the counting unit so that it leads to 100 grams. SUGAR GRINDER Turbulence System and Steam Extraction: APPLICATION: The machine is used to granule (crystal) sugar to make it in powder form for using in biscuit recipe. DESIGN: Hammer Mill type, body of the machine is fitted on a sheet metal box/container/receiver with one air exhaust balloon. The driving motor is fitted on the top of the box. In case of auto feeding a bucket elevator is fitted at one end of the box. OUTPUT: 10 Kg/min. (icing sugar) FEEDING: Automatic POWER LOAD: 5 HP for grinder, 1 HP for auto feeder with built-in control panel MULTIPACK WRAPPING MACHINE This machine helps in wrapping the biscuits on the particular wrapper fixed on the roller of the machine. The wrapper is feed into the machine and the sealing of the wrapper is done by four heater roller, which is fitted on the machine. This heater roller heat up the plastic and seals the packet. And at the same time the jaw cutter cut the packet on the cutting edge marked i.e. as per the grams of the packet which is feed in the automatic machine (100 120, 120 150, 150 -170, 170 - 190). The packets coming out from the wrapping machine in a minute is programmed in computer and can be changed as per the need.

POLY BAGS Poly bags contain 24 packets of parle g biscuits in one poly bag. There are 4 workers employed on this section who take care of the work by putting 24 packets of biscuits in the bag and forwarding it to sealing machine section.

SEALING MACHINE The sealing machine has heater rod for sealing the poly bag in which 24 packet of biscuit are placed, and it have a conveyer belt on other side so that when the poly bag passes through the heater and get sealed then it is passed to the tapping machine.

TAPPING MACHINE Six such poly bags are placed in one such corrugated box and the box is passed through the tapping machine where are tapped and then sent through a long diversion conveyer belt. This belt helps to transfer the box to the dispatch section directly. 36 boxes are arranged on pallet in the dispatch section, from where they are transferred to the various dealers all over the India and world wide.

MACHINERY USED IN MAINTENANCE OF MAJOR MACHINERY Laphe Drilling machine Shaper Miller Pantograph and many more.

USE OF COST CUTTING MEASURES. For example: All the biscuits are manufactured in this factory i.e. In Mumbai one as the load of work exceeded many factories were set up in other states of India. So the cost of transportation decreases and more profit is earned. Another example is of Hide and Seek one of the products of the company, for which they used to import chocolate chips from Australia but later when it was available in Chennai so the import was stopped and the cost dropped by a rupee because the duty which was on the import was high and then another supplier was found in Hyderabad and the price was again reduced by a rupee which finally ended up at 14 rupees.