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INTRODUCTION
Britannia industries ltd. Unit Rudrapur was established on 1st April’05 in the

area of approx. 20 acres mainly for the purpose of production of biscuits as this is

almost free from all types of taxes.

In Britannia Industries ltd., there are many departments which are inter

connected to each other and work together for the welfare of the company as the

whole. There is well built communication system inside a company which help

doing work on time with efficiency and effectiveness.

The department includes Quality assurance, store, production, packaging and

Dispatch, Engineering, Maintenance, purchase, Finance, Legal and Administrative

and personnel and Training.

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COMPANY PROFILE

The story of one of India's favorite brands reads almost like a fairy tale. Once upon

a time, in 1892 to be precise, a biscuit company was started in a nondescript house in

Calcutta (now Kolkata) with an initial investment of Rs. 295. The company we all

know as Britannia today.

The beginnings might have been humble-the dreams were anything but. By 1910,

with the advent of electricity, Britannia mechanized its operations, and in 1921, it

became the first company east of the Suez Canal to use imported gas ovens.

Britannia's business was flourishing. But, more importantly, Britannia was acquiring

a reputation for quality and value. As a result, during the tragic World War II, the

Government reposed its trust in Britannia by contracting it to supply large quantities

of "service biscuits" to

As time moved on, the biscuit market continued to grow… and Britannia grew along

with it. In 1975, the Britannia Biscuit Company took over the distribution of biscuits

from Parry's who till now distributed Britannia biscuits in India. In the

Subsequent public issue of 1978, Indian shareholding crossed 60%, firmly

establishing the Indianness of the firm. The following year, Britannia Biscuit

Company was re-christened Britannia Industries Limited (BIL). Four years later in

1983, it crossed the Rs. 100 cores revenue mark.

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On the operations front, the company was making equally dynamic strides. In 1992,

it celebrated its Platinum Jubilee. In 1997, the company unveiled its new corporate

identity - "Eat Healthy, Think Better" - and made its first foray into the dairy

products market. In 1999, the "Britannia Khao, World Cup Jao" promotion further

fortified the affinity consumers had with 'Brand Britannia'.

Britannia strode into the 21st Century as one of India's biggest brands and the pre-

eminent food brand of the country. It was equally recognized for its innovative

approach to products and marketing: the Lagaan Match was voted India's most

successful promotional activity of the year 2001 while the delicious Britannia 50-50

Maska-Chaska became India's most successful product launch. In 2002, Britannia's

New Business Division formed a joint venture with Fonterra, the world's second

largest Dairy Company, and Britannia New Zealand Foods Pvt. Ltd. was born. In

recognition of its vision and accelerating graph, Forbes Global rated Britannia 'One

Amongst the Top 200 Small Companies of the World', and The Economic Times

pegged Britannia India's 2nd Most Trusted Brand

Today, more than a century after those tentative first steps, Britannia's fairy tale is

not only going strong but blazing new standards, and that miniscule initial

investment has grown by leaps and bounds to crores of rupees in wealth for

Britannia's shareholders. The company's offerings are spread across the spectrum

with products ranging from the healthy and economical Tiger biscuits to the more

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lifestyle-oriented Milkman Cheese. Having succeeded in garnering the trust of

almost one-third of India's one billion population and a strong management at the

helm means Britannia will continue to dream big on its path of innovation and

quality. And millions of consumers will savor the results, happily ever after.

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COMPANY BOARD OF DIRECTORS

Designation
Name

Chairman
Mr. Nusli Neville Wadia
Managing
Ms. Vinita Bali
Director
Mr. A.K.Hirjee
Director
Dr. Ajai Puri
Director
Mr. Avijit Deb
Director
Mr. Jeh N Wadia
Director
Mr. Keki Dadiseth
Director
Mr. Nasser Munjee
Director
Mr. Ness Nusli Wadia
Director
Mr. Nimesh N Kampani
Director
Mr. Pratap Khanna
Director
Mr. S.S.Kelkar
Director
Dr. Vijay L. Kelkar
Director

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MANAGEMENT TEAM

ANURADHA NARASIMHAN - Category Director - Health & Wellness

ASHOK KUMAR GUPTA - General Manager - Accounts & Planning

B. PRASHANTH - Head of R&D

BALAJI REDDIPALLI - Head Replenishment

Dr. K.N. SHASHIKANTH - Head - Corporate Quality

GAUTAM BANERJEE - General Manager - Materials

JITENDRA MAHAJAN - Head - Procurement

KAILASH H. KAKANI - General Manager – Manufacturing Operations

N. VENKATARAMAN - General Manager - Commercial

P. GOVINDAN - Company Secretary & Head of Legal

R. ANAND - Business Operations Director

R K AGRAWAL - Supply Chain Director for New Business

Development

SHALINI DEGAN - Category Director - Delight & Lifestyle

SHRIDHAR PANSHIKAR - National Sales Director

T S VENKETRAM - General Manager - Engineering Projects &

Technology

VALIVETI V PADMANABHAM - Head - Corporate I

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MILE STONES:

1892

• The Genesis - Britannia established with an investment of Rs. 295 in

Kolkata

1910

• Advent of electricity sees operations mechanised

1921

• Imported machinery introduced; Britannia becomes the first company

East of the Suez to use gas ovens

1939 - 44

• Sales rise exponentially to Rs.16,27,202 in 1939

• During 1944 sales ramp up by more than eight times to reach Rs.1.36

crore

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1975

• Britannia Biscuit Company takes over biscuit distribution from Parry's

1978

• Public issue - Indian shareholding crosses 60%

1979

• Re-christened Britannia Industries Ltd. (BIL)

1983

• Sales cross Rs.100 crore

1989

• The Executive Office relocated to Bangalore

1992

• BIL celebrates its Platinum Jubilee

1993

• Wadia Group acquires stake in ABIL, UK and becomes an equal

partner with Groupe Danone in BIL

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1994

• Volumes cross 1,00,000 tons of biscuits

1997

• Re-birth - new corporate identity 'Eat Healthy, Think Better' leads to

new mission: 'Make every third Indian a Britannia consumer'

• BIL enters the dairy products market

1999

• "Britannia Khao World Cup Jao" - a major success! Profit up by 37%

2000

• Forbes Global Ranking - Britannia among Top 300 small companies

2001

• BIL ranked one of India's biggest brands

• No.1 food brand of the country

• Britannia Lagaan Match: India's most successful promotional activity

of the year

• Maska Chaska: India's most successful FMCG launch

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2002

• BIL launches joint venture with Fonterra, the world's second largest dairy

company

• Britannia New Zealand Foods Pvt. Ltd. is born

• Rated as 'One amongst the Top 200 Small Companies of the World' by

Forbes Global

• Economic Times ranks BIL India's 2nd Most Trusted Brand

• Pure Magic -Winner of the Worldstar, Asiastar and Indiastar award for

packaging

2003

• 'Treat Duet'- most successful launch of the year

• Britannia Khao World Cup Jao rocks the consumer lives yet again

2004

• Britannia accorded the status of being a 'Superbrand'

• Volumes cross 3,00,000 tons of biscuits

• Good Day adds a new variant - Choconut - in its range

2005

• Re-birth of Tiger - 'Swasth Khao, Tiger Ban Jao' becomes the popular chant!

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• Britannia launched 'Greetings' range of premium assorted gift packs

• The new plant in Uttaranchal, commissioned ahead of schedule.

• The launch of yet another exciting snacking option - Britannia 50-50 Pepper

Chakkar

2006

• Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an

international large sized biscuit pack.

• Britannia acquires 51% stake in Bangalore-based bakery foods retailer Daily

Bread.

2007

• Britannia industries formed a joint venture with the Khimji Ramdas Group

and acquired a 70 percent beneficial stake in the Dubai-based Strategic

Foods International Co. LLC and 65.4% in the Oman-based Al Sallan Food

Industries Co. SAOG.

• Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits

to be be launched in India with "No Added Sugar" (Variants - Chocolate

Cream, Orange Cream, and Litetime)

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2008

• Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the

goodness of 5 health Cereals, and sweetened with Natural honey. Britannia

Nutrichoice promised consumers "Bhook Bhagao, Kuch Healthy Khao"

• Britannia launched Iron fortified 'Tiger Banana' biscuits, 'Good Day Classic

Cookies', Low Fat Dahi and renovated 'MarieGold'.

2009

• Britannia Launches ActiMind - A first of its kind milk based health drink for

kids, which helps improve mental sharpness. Launch of ActiMind marked

Britannia's entry into the beverage segment and has further extended its

credo of 'Eat Healthy, Think Better' to 'Drink Healthy, Think Better' as

well!!

• Britannia NutriChoice Nature Spice Crackers launched - Your favorite

Cream Crackers, now made even more exciting with the addition of "Sabut"

Ajwain and Jeera spices.

• Britannia takes full control of Daily Bread.

• Britannia Industries buys out New Zealand's Fonterra from existing dairy

joint venture, Britannia New Zealand Foods (BNZF). BNZF became a 100

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per cent Britannia subsidiary and was renamed Britannia Dairy Private

Limited (BDPL).

• Recognizing the changing global trends & health benefits of removing

transfats, Britannia is the first Bakery brand in India to remove transfats

from its products.

• Wadia Group acquired stake holdings from Group Danone and becomes the

single largest shareholder in BIL.

2010

• 50-50 Maska Chaska was re-launched with a new masaaledar twist - a

delightful blend of butter and imported flavours along with sprinkling of

masala in September 2010.

• Tiger enters the Cookies category, with the launch of Krunch Cookies in

October. These cookies are not only high on delight but also high on energy

and have been created keeping in mind the needs of today's kids, These

delightful cookies come in two exciting variants - Fruit & Nut and

Chocochips and at an affordable price point of just Rs 5.

• Brand NutriChoice, in keeping with its track record of launching

differentiated healthy snacks, launched Diabetic Friendly Essentials on 14th

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November, a day that is world over recognized as World Diabetes Day. The

range comprised of 2 variants - Oats Cookies and Ragi Cookies - and is

available in top Indian cities.

• Britannia was presented the Master Brand 2010 Award by CMO Council in

November 2010.

• Rotary Club of Chennai awarded CSR Award to Britannia in November, for

our work in nutrition.

2011

• Always committed to constant innovation, Britannia launched Britannia

Healthy Start in Mumbai in January 2011. Specially designed with Indian

tastes in mind, Healthy Start is a complete range of ready-to-cook breakfast

mixes of Upmas, Pohas, Porridges and Oats that are healthy, delicious, and

take just 5 minutes to cook! This is the only product range in its category

that combines

the natural nutrition of multi-grains, 100% real vegetables, pulses and nuts

all in one pack.

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• Britannia received the Most Respected Company Award 2011 from

Businessworld.

• Bourbon received the Most Popular Confectionery Product Preferred By

Youth (Biscuit) Award.

• IMCRBNQA (Indian Merchant Chambers Ramakrishna Bajaj National

Quality Award) conferred the Manufacturing Performance Excellence

Trophy a National Quality Award for the 2010 cycle, for Britannia Corporate

Office (Bangalore), Britannia Industries Ltd. (Rudrapur) and Sunandram

Foods Pvt Ltd (Mangaldoi, Guwahati).

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ABOUT RUDRAPUR PLANT

Total plot area 440 X 180 = 79200 sq m.

Production trail started on 1st April 2005.

TIGER product approved on 15th April 2005.

GOOD DAY approved on 20th May 2005.

50-50 approved on 19th October 2005.

Unit recommended for ISO22000 on 24th March 2006.

Cream plant commenced with ORANGE TREAT followed by Bourbon in July 2006

SQC/SPC implemented for the first time on 50-50 line from October 2006.

GOOD DAY pile pack production started on December 2006.

Commercial production of MASKA CHASKA by the end of 2006.

TQM initiative started in the GOOD DAY line from February 2007.

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Total production of company is 7000 tons per month. Biscuits manufactured in this

Rudrapur plant are-

1. Good Day Butter

2. Good Day cashew

3. Good Day Pista Badam

4. 50-50

5. Maska Chaska

6. Pure magic vanilla and Pure Magic Chocolate.

7. Milk Bikies milk cream.

8. Bourbon

9. Orange Treat-O

10.Time Pass

Ingredients and their storage

1. Flour- Refined wheat flour

2. Fats/Oil

a. Refined Palm Oil.

b. Palmolin Oil

3. Sweetening Agent

a. Crustal Sugar

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b. Liquid glucose

4. Dairy food

a. Butter

b. Skimmed milk powder

c. Condensed milk

5. Yeast- compressed yeast

6. Enzymes

a. Papain

b. Neutrase

c. Dopeh Enzyme

d. Fungamyl 8001

7. Colors

a. Ponceau

b. Tartrzine

8. Flavours

a. Ethyl vanillin

b. Butter flavor

c. Cocoa powder

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d. Black jack

9. Emulsifier

a. Lecithin

b. GMS

c. Solbake

10.Antioxidant

a. TBHQ

b. BHA

11.Aerating Agent

a. Ammonium bicarbonate

b. Sodium bicarbonate

12.Chemicals

a. NaCl

b. Citric Acid

c. Lactic Acid

d. SMBS

e. Propylene Glycol

f. Dibasic Ca phosphate dehydrate

13.Nuts

a. Cashew nuts
b. Pista
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c. Almond

14.Essence

15.Others

a. Chives

b. Black powder

16.Packing material

a. Cardboard boxes

b. Laminated rolls

c. 3-ply liners.

All the ingredients are first received by storage department and a receipt slip of

ingredient is sent to Quality control lab to check the Quality of ingredients. The total

production of BIL, Rudrapur is around 250 tons. The consumption of various

ingredients per day is-

 175 tons of wheat flour

 55 tons of sugar

 40 tons of palm oil

 4 tons SMP

 4 tons of cashew

 4 tons of palmolin oil
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There are also 2 cold stores in the plant for the storage of edible chemical like butter,
compressed yeast, chocolate, Vanilla, Cocoa etc. flavours. There is silo for the online
storage wheat flour with the capacity of 60 tons. There are 6 tanks of capacity 40 KL
each for palm oil. For the oven system there are 4 tanks of fuel (L.D.O. and L.V.F.O.)
with the capacity of 50 KL each.
In the pre mixing area following tanks are present:

 Palmolin oil (2 in no.)
 Sugar solution (1 in no.)
 HVO (1 in no.)

Acceptance criteria of ingredients

1. Wheat flour
 Moisture %: 14% (max)
 Total ash % : 0.8% (max)
 Acid insoluble ash % : 0.05 % (max)
 Alcoholic acidity % : 0.12 % (max)
 Gluten (dry weight basis) % : 7.5% (min)
 Germ oil acidity % : 15 (max)
 Granularity % : 85 mesh sieve (90% should pass through)
 Sedimentation value : 17-30
 Taste and color: Should be characteristic.
 Extraneous material: Should be absent.
 Origin: Should be vegetable origin

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2. Palm oil
 FFA % : 0.10 % (max)
 Moisture % : 0.10 % (max)
 Peroxide value :1.5 (max)
 Saponification value : 195-205
 Iodine value : 45-56
 Melting point : 370 C

3. Sugar
 Moisture % : 0.1%
 Total sugar % : 99.5%

4. Baker’s yeast
 Moisture % : 7.5%
 Dough raising capacity: 125 (min)
 Fungal -amylase activity: 800-920 FAU/gm.

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Table standard moisture content for ingredients:

Ingredients Moisture content (max.)
1. Flour 14
2. Maize Starch 13
3. Sugar 0.1
4. Liquid glucose 16
5. SMP 5
6. FCCM 29
7. Whey powder 5
8. Compressed yeast 75
9. Carmel 45
10.GMS 2.75
11.Free flowing salt 0.1
12.Iodized salt 1.25
13.ACP 1.25
14.Citric acid Monohydrate 8.8
Anhydrous 0.5
15.Potassium iodide 1
16.Calcium carbonate 2
17.Cashew bits 5
18.Almonds bits 5
19.Pista 7
20.Alkalined cocoa powder 5
21.Dehydrate chives 7
22.Ethyl vanillin 10
23.Chocolate 3
24.Cocoa mass 3

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STANDARD AND CERTIFICATIONS IN BIL, RUDRAPUR

ISO22000:
ISO22000 is intended to define the requirement for companies that desire to exceed
the regularity requirement for food safety.
It is an international standard for any business in food chain from „farm to far‟ and it
include organization such as producers of equipments, packaging, cleaning agents,
additives and ingredients. ISO22000 is also for companies seeking to integrate their
quality and food safety management system.
Following are the benefits of ISO22000 for any organization are:
 Applies to all organization in the global food chain.
 A truly global standard.
 Provides potential for harmonization of national standard.
 Covers the majority of requirements of the current retailer food safe standard.
 Complies the codex HACCP concepts internationally.
 An audible standard which provides a framework for third party certification.
 Audible standard with clear requirement.
 Suitable for regulators.
 The structure aligns with the management system clause of ISO9001 an ISO14001.
 Enable communication about hazards with partners in the chain.
 Better planning, less post process verification.
 Improved documentation.
 Dynamic communication on food safety issue with suppliers, customers,
regulators and other interested parties.

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ISO9001:
The ISO9000 standards were brought by international Organization for
standardization & HACCP standard by the code alimentation commission (CAC).
ISO9000 encompasses all the activities of a company to ensure that it meets the
quality objectives with HACCP is directed toward ensuring food safety application of
HACCP adds value of the ISO9000 quality management system. A combined effect of
both would provide safe & wholesome food to the consumer. Therefore the best way
to use ISO9000 rout to manager HACCP

PFA 1954:
It is the prevention of Food Adulteration Act 1954. The rules were formed in 1955;
this law was made to prevent any kind of food adulteration and to make laws which
are applicable equally to all. The regulation regulates product manufactured,
packaging, storage & sale of foods & food products.
Food is said to be adulteration:
If it contains poisonous/injurious material.
If it contain filth or decomposed material.
If it contain harmful or unapproved material.
If it is misbranded.
If it contaminants exceed the permissible limits.
If additives are added in exceed.
If it is package in unsuitable packaging material.

Directorate General Health Service comes under Dept. of Health & Family Welfare is
the nodal agency for PFA central committee for food standard is responsible for
formation/ amending the food laws under PFA.

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Hazard analysis and critical control point (HACCP):

It is a systematic preventive approach to food safety and pharmaceutical safety that
addresses physical, chemical and biological hazards as a means of prevention rather
then finished product inspection. HACCP is used in the food industry to identify
potential food safety hazards, provide method to remove them, define their critical
limits, methods for verification and documentation. So the key actions, known as
Critical Control Point (CCPs) can be taken to reduce or eliminate the risk of hazards
being realized. The system is used at all stages of food processing including packaging
and distribution.

New concept like 5S i.e. SEIR I: Organization, SEITON: Neatness, SEISO:
Cleanliness, SEIKETSO: Standardization, SHITSUKE: Discipline, are being
implemented in BRITANNIA INDUSTRIES LIMITED.

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THE ORIGIN OF “EAT HEALTHY THINK BETTER”

Britannia -the 'biscuit' leader with a history-has withstood the tests of time. Part of the

reason for its success has been its ability to resonate with the changes in consumer

needs-needs that have varied significantly across its 100+ year epoch. With consumer

democracy reaching new levels, the one common thread to emerge in recent times has

been the shift in lifestyles and a corresponding awareness of health. People are

increasingly becoming conscious of dietary care and its correlation to wellness and

matching the new pace to their lives with improved nutritional and dietary habits. This

new awareness has seen consumers seeking foods that complement their lifestyles

while offering convenience, variety and economy, over and above health and

nutrition.

Britannia saw the writing on the wall. Its "Swasth Khao Tan Man Jagao" (Eat Healthy,

Think Better) re-position directly addressed this new trend by promising the new

generation a healthy and nutritious alternative - that was also delightful and tasty.

Thus, the new logo was born, encapsulating the core essence of Britannia - healthy,

nutritious, optimistic - and combining it with a delightful product range to offer

variety and choice to consumers.

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HISTORY OF BISCUITS
Sweet or salty. Soft or crunchy. Simple or exotic. Everybody loves munching on

biscuits, but do they know how biscuits began?

The history of biscuits can be traced back to a recipe created by the Roman chef

Apicius, in which "a thick paste of fine wheat flour was boiled and spread out on a

plate. When it had dried and hardened it was cut up and then fried until crisp, then

served with honey and pepper."

The word 'Biscuit' is derived from the Latin words 'Bis' (meaning 'twice') and 'Coctus'

(meaning cooked or baked). The word 'Biscotti' is also the generic term for cookies in

Italian. Back then, biscuits were unleavened, hard and thin wafers which, because of

their low water content, were ideal food to store.

As people started to explore the globe, biscuits became the ideal travelling food since

they stayed fresh for long periods. The seafaring age, thus, witnessed the boom of

biscuits when these were sealed in airtight containers to last for months at a time. Hard

track biscuits (earliest version of the biscotti and present-day crackers) were part of

the staple diet of English and American sailors for many centuries. In fact, the

countries which led this seafaring charge, such as those in Western Europe, are the

ones where

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biscuits are most popular even today. Biscotti is said to have been a favourite of

Christopher Columbus who discovered America!

Making good biscuits is quite an art, and history bears testimony to that. During the

17th and 18th Centuries in Europe, baking was a carefully controlled profession,

managed through a series of 'guilds' or professional associations. To become a baker,

one had to complete years of apprenticeship - working through the ranks of

apprentice, journeyman, and finally master baker. Not only this, the amount and

quality of biscuits baked were also carefully monitored.

The English, Scottish and Dutch immigrants originally brought the first cookies to the

United States and they were called teacakes. They were often flavoured with nothing

more than the finest butter, sometimes with the addition of a few drops of rose water.

Cookies in America were also called by such names as "jumbles", "plunkets" and "cry

babies".

As technology improved during the Industrial Revolution in the 19th century, the

price of sugar and flour dropped. Chemical leavening agents, such as baking soda,

became available and a profusion of cookie recipes occurred. This led to the

development of manufactured cookies.

Interestingly, as time has passed and despite more varieties becoming available, the

essential ingredients of biscuits haven't changed - like 'soft' wheat flour (which

contains less protein than the flour used to bake bread) sugar, and fats, such as butter

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and oil. Today, though they are known by different names the world over, people

agree on one thing - nothing beats the biscuit!

Some interesting facts on the origin of other forms of biscuits:

The recipe for oval shaped cookies (that are also known as boudoir biscuits, sponge

biscuits, sponge fingers, Naples biscuits and Savoy biscuits) has changed little in 900

years and dates back to the house of Savoy in the 11th century France. Peter the Great

of Russia seems to have enjoyed an oval-shaped cookie called "lady fingers" when

visiting Louis XV of France.

The macaroon - a small round cookie with crisp crust and a soft interior - seems to

have originated in an Italian monastery in 1792 during the French Revolution.

SPRING-uhr-lee, have been traditional Christmas cookies in Austria and Bavaria for

centuries. They are made from a simple egg, flour and sugar dough and are usually

rectangular in shape. These cookies are made with a leavening agent called

ammonium carbonate and baking ammonia.

The inspiration for fortune cookies dates back to the 12th and 13th Centuries, when

Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their

defense against Mongolian invaders.

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INGREDIENT FUNCTION AND BISCUIT PROCESSING

Ingredients:

Major Ingredients:

Flour: Generally, flour is the ingredient that fives baked goods their form and

structure. When the flour is mixed with water, the proteins in flour interact with each

other to form gluten. The proteins are namely glutelin and gliadin which formas the 3-

dimensional network of gulten. Gluten is what gives the dough its elasticity and the

ability to stretch. The gluten entraps CO2 released by chemical leavening agents and it

also entraps air while mixing which results in unique expansion of the dough. All

operation like stirring, folding, mixing etc causes the gluten network to develop. The

more the mixing stronger is the gluten network.

Sugar: It imparts sweet taste, improves texture, crust colour and extends shelf-life.

Selection of the proper sweetener is to provide. The principal sweetener used is

sucrose (granulated sugar). Corn syrup, high fructose corn syrup, cookies. The colr of

Biscuits is achieved due to

caramelization sugar at higher temperature .Sugar being hygroscopic in nature helps in

moisture retention. It also has a softening action on gluten rendering it more

extensible.

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Fat: Fat acts as conditioning agent. Fat lubricates the structure of a baked product. It

has tenderizing effect on flour proteins and makes the product tender. Fat improves

the eating

quality for prolonged period. It also modifies other flavours, enhance sweetness of

sugar and decrease sourness of acids.

Water: Water is required to mix well the above ingredients. It is the basic ingredient

because of which the guten network develops.

Palm oil: palm oil is extracted from the pulp of the fruit of the oil palm. Palm oil is

naturally reddish in colour because it contains a high amount of beta-carotene. It is a

highly saturated vegetable fat. Palm oil is semi-sold at room temperatures. Palm oil

contains several saturated and unsaturated fats in the forms of glyceryl laurate (0.1%

saturate), myristate (1% saturated), palmitate (44% saturated), stearate (5% saturated),

oleate (39%, monounsaturated), Iinoleate (10%,polyunsaturated), and linolenate

(0.3%, polyunsaturated). Palm oil does not contain cholesterol. It is used as it has a

higher oxidative stability and lower cost. It helps in extending shelf life: maintain

flavor stability and gives smoothness to the bite of the Biscuits.

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MINOR INGREDIENTS:

• Leaving agent

Ammonium bicarbonate: This is a white crystalline salt. It is extremely used as

leavening agent as it decomposes completely when heated. It breaks down completely

into ammonia, carbon dioxide and water there by leaving no residue. Ehen ammonium

carbonate or bicarbonate is heated CO2 is produces. However, the ammonia imparts a

detectable odour unless it is completely removed. It is used in biscuits and crackers as

they have large surface to mass ratio and ammonia escapes when baked at high

temperature. It can be use in products that are to be baked at low moisture.

Sodium bicarbonate: It will liberate CO2 gas, a leavening gas, when heated. It also

liberates the same gas when mixed with an acid, either hot or cold. It is used as a

means of adjusting and controlling acidity of the biscuit. The popularity of sodium

bicarbonate as a gas source is based on its low cost, lack of toxicity, ease of handling

very small contribution to the taste of the ind product. It also helps on maintaining the

structure of the biscuit when puffing occurs in the baking oven.

• Emulsifier-Lecithin

Acts as an emulsifying agent. It is used for binding of fat and water molecules.

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• Salt: Salt is a seasoning that sharpens the flavour of other ingredients. If the

amount of salt called for in recipe is reduced, other seasonings should be increased to

compensate for the flavour loss. Salt will also enhance the sweetness of a food.The

salt in yeast dough solws the fermentation of the yeast, so reducing the amount of salt

used will affect the finished product.

• SMP: A fat-free varity of milk powder that contains no more then 5% if milk fat.

Skim milk can be interchanged with low-fat or whole milk in recipe without a notice

able difference in the end product. It‟s also aids to surface coloring of biscuits.

• GMS: Glycerol monostearate. It‟s us an organic molecule and is used as a

emulsifier. GMS is a colour less order less and sweet tasting flaky powder that is

hygroscopic. It is a glycerol ester of stearic acid. GMS is a food additive used as a

thickening, emulsifying and preservative agent. GMS is largely used in baking

preparations to add “body” to the food.

• CARAMEL: Sugar that has been slowly heated until it melts and becomes

slightly burned. Once the sugar has melted, it take on varying degrees of color and

develops a distinct flavour.

• INVERT SYRUP: It is the inversion sugar syrup which is made by the action

of citric acid. Inverting sugar means breaking the basic sugar or sucrose in its basic

elements glucose and fructose. It has numerous advantages in baking:

34

a) It is more hygroscopic i.e. it helps in more water retention.

b) It has the ability to stay in liquid form for longer time period.

c) Compared with basic sugar it is sweeter and its products tend to remain moisture

and ate less prone to crystallization.

d) It has a lower water activity than sucrose so it provides more powerful preserving

qualities i.e. longer shelf life of product.

Processing of biscuits

The processing of biscuits consists of following steps

• MIXING: Mixing process involves

Dry creaming or Mixing: This process involves the dry mixing of fat, flour,

sugar, salt and other emulsifying ingredients.

Wet creaming or Mixing: This process involves after the dry creaming and

here palm oil and water is added to the above mixer.

STANDING OF DOUGH: For the formation of good dough, proper maturation

of gluten protein is essential. So after mixing the dough is given a standing time for

the gluten maturation. This process is very essential for the hard dough or cracker

variety biscuits

35

This is a process where all ingredients are put together in right proportion for dough

formation. These ingredients are then fed into mixture is done and dough is prepared

for moulding. Major ingredients are flour, fat, sugar and others as per the products

one would like to have. Dough temperatures play important role in biscuits

manufacturing. Next important factor is mixing time.

Mixing time depends upon folur characteristics. Noramally mixing time is between

10-15 min and is performed in two or three stages with different mixing speed.

B) Forming: forming consists of

• Sheeting

• Gauging and

• Moulding/cutting

In this section we laminate the dough into sheet which the passes down to gauge

roller sheet thickness is achieved for cutting. Here we have a cutter or a moulder as

per the variety where one gets the shape and sizes of biscuits. Moulder/cutter speed

again depends on different variety of biscuits. Moulders are used for short dough

type of biscuits and cutters are used for sheet variety or hard dough.

36

C) Baking: This is the area where we pass these moulded wet biscuit into baking

oven. The biscuits are baked on desired temperatures. Various type of heating are

available now a days as per the convenience and cost. Different type ovens are

available like direct fired, indirect fired and hybrid ovens. Heating of biscuit is done

by conduction,convection and radiation inside the oven. Dampers are

provided to control moisture inside the oven section. Different heating profiles are

maintained for different varities of biscuits.

The baking oven installed in this plant is an indirect heat oven consisting of 7

zones that cover 300ft length.

The different zones of this oven are classified as

1) Heating zones (zones 1,2 and 3) – in this zone puffing of biscuits occurs.

Puffing is enhanced by ammonium carbonate. Moisture is removed due to

heating.

2) Baking zone (zone 3,4 and 5)- here cooking of the biscuits occur.

3) Colouring zone (zone 5,6 and 7) – due to caramelisation and millard
browning of sugar the colour formation occurs in this zone.

37

PHYSICAL CHANGES: during baking formation of crust melting of fat gas
expansion in dough pieces, water converted into steam etc.

CHEMICAL CHANGES: due to baking process are gas formation, starch
gelatinization. Protein changes, caramelisation of sugar and dexterisation.

D) COOLING: These baked biscuits are then past on to cooling conveyors
for natural cooling prior to packing. When biscuits comes out with oven the
temperature of biscuits is around 100 degree celcious these biscuits can be
cooled by letting it travel for distance 1.5 times of baking time so if a oven
of 300ft then cooling conveyor length would be 450ft. natural cooling
preffered over forced colling as it maintains the texture quality of biscuit.
After cooling temperature comes down to around 45 degree celceous.
E) PACKING: These biscuits are then stacked in a stracker machine and fed into
packing machine for packing. Different packing material is available for packing
of these biscuits in different packs. slug pack or family packs etc.

these packs are then put in to secondary packaging like cartoons to be
transported to retailers.

38

EXCUTIVE SUMMARY

Britannia is the market leader in the organized biscuit and bakery product market in

India. Bakery product accounts for 90% otf the revenues and includes biscuits, bread

and cake & Rusk. Dairy products contribute to 10% of Britannia‟s annual turnover. As

the company has started its manufacturing unit Five year back in Uttarakhand, wants

to take full advantage through volume sales and maximize its market share in

Uttarakhand. Company wants to reduce its cost of distribution, cost of transportation,

strengthen its distribution channel to take full support of the channel member in

increasing the sales and reducing the cost and wants to get competitive advantage over

its competitors PARLE, PRIYAGOLD, and ITC.

The FMCG market is set to treble from US $11.6 billion in 2003 to US $33.4 billion

in 2015 penetration level as well as per capita consumption in most product categories

like jams, toothpaste, skin care, hair wash etc in India is low indicating the untapped

market.

India- A large consumer goods spender:

An average Indian spends around 40% of his income on grocery and 8% on personal

care products. The large share of FMCG in total individual spending along with the

large population base is another factor that makes India one of the largest FMCG

markets.

39

GOAL OF THE COMPANY

I. Investing in appropriate technology.

II. Working collaborators with the business partners.

III. Quality products to customers.

IV. Continuous training and retraining of the employees to create culture that

value quality and food safety as a core pillar of the business.

IV. To control the wastage and save time and efforts.

V. To work under the principals of Kaizen, HACCP.

40

SWOT ANALYSIS OF BRITANNIA

Strength Weakness
Fulfill one of our Basic Decreases nutritional value
Requirement among Air , Water , Increases the cost of food product
Food, Shelter Industry and technology requires
Widely accepted in all Generations high investment
Easily available in various forms Regular usage of processed food
Provide good Instant Remedy for can cause alteration in health
hunger in the form of readymade
food
Preserves the non seasonal food
and makes it available all
throughout the year

Opportunities Threats
Increase economy of India Many companies are result
Generate employment opportunity oriented
Good quality of Goods Increase in pollution
Provide competition to foreign Sometimes provide poor quality of
companies product for more profit
Improve living standard Lack of technology
Provide goods to nation at cheaper Unable to utilize all the resources
rate efficiently
Inflow of foreign reserve and funds
for the govt.(taxes)

41

OBJECTIVE OF STUDY

The project which I got is to observe the each machine of plants and check the

problem which comes in packet of biscuits like:

To analysing Cuts in biscuits packets during the packaging process.

To analysing Open biscuits packets during the packaging process.

To analyse Joint biscuits packets during the packaging process.

To analyse under weight problem during the packaging process.

To analyse Coding problem during the packaging process.

To analyse Breakage problem during the packaging process.

42

SCOPE OF STUDY

The project is cover the study of training & development program at staff level at the

SIDCUL, Rudrapur, Uttarakhand unit of Britannia Industries. The department in which

survey was conducted are as follows:

PACKAGING DEPT.

MAINTENANCE DEPT.

BAKING SECTION

PRODUCTION DEPT.

The employees is different department of the organization have full co-operation and

support by frankly answering the question.

43

RESEARCH METHODOLOGY

Data sources:

Primary data.

Secondary data.

Primary sources:

Primary data was taken from Analyzing Plant machines. There are four plant lines

and every plant line having 4 to 5 machines, all the primary data was gathered from

those machines. Thus the relevant information related to the assessment parameters

was helpful to know the “Study of machines” of Production and Operations.

Secondary Sources:

Historical records: data regarding the origin and the history of the organization

were obtained from the historical records of the organization.

SAMPLE SIZE: 16 Machines. (1000 packets of biscuits from each machine)

44

RESEARCH INSTRUMENT:

The data was collected through a structured chart to gather information from

machines.

SAMPLING PLAN:

Various machines of plants like Cream Plant, 50-50 plant, Good day (Pista Badam),

and Good day (Butter) Plants.

DATA ANALYSIS:

Percentage method & through the help of chart.

45

DATA ANALYSIS AND
INTERPRETATION

46

OBSERVATION 1
DATE: 28-07-2011

PLANT: 1

Observation of 1200 biscuit packets in each machine of plant one
Total observation in plant one is 7200

PROBLEMS M1 % M2 % M3 % M4 % M5 % M6 %
1) Cutting 4 .33 4 .33 16 1.3 13 1.0 10 .83 12 1
2) Open 3 .25 6 0.5 14 1.1 15 1.2 8 .66 8 .66
3) Joint 3 .25 15 1.2 8 .66 6 0.5 10 .83 10 .83

4) U/W 25 2.0 40 3.3 15 1.2 15 1.2 21 1.7 17 1.4

5) Breakage 5 .41 3 .25 10 .83 3 .25 __ __ 2 .16
6) Coding __ __ __ __ __ __ __ __ 5 .41 __ __
TOTAL 40 3.3 68 5.6 63 5.2 52 4.3 54 4.5 49 4.0
PROBLEMS

M = Machine
% = Problems in percentage
Total no of Biscuits packets observed = 7200
Total no of problems in Biscuits packets = 326
Total no of perfect Biscuit packet = 6874
Perfect Biscuits packet in % = 95.47
Problems Biscuits packet in % = 4.52

47

DATE: 28-07-2011

PLANT: 2


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 11 .91 6 0.5 12 1 13 1.1 41 3.4
2) Open 13 1.1 15 1.2 15 1.2 6 0.5 35 2.9
3) Joint 12 1 17 1.4 18 1.5 15 1.2 67 5.5

4) U/W 25 2.0 15 1.2 9 .75 13 1.1 23 1.9

5) Breakage 3 .25 2 .16 __ __ __ __ 12 1
6) Coding __ __ __ __ __ __ __ __ __ __
TOTAL 64 5.3 55 4.5 54 4.5 47 3.9 178 14.8
PROBLEMS

Total no of Biscuits packet observed = 6000

48

DATE: 28-07-2011

PLANT: 3


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 8 .66 14 1.3 8 .66 11 .91 8 .66
2) Open 13 1.1 21 1.7 11 .91 13 1.1 5 .41
3) Joint 10 .83 11 .91 28 2.3 16 1.3 9 .75

4) U/W 22 1.8 18 1.5 16 1.3 20 1.6 11 .91

5) Breakage 3 .25 5 .41 4 .33 13 1.1 __ __
6) Coding __ __ __ __ __ __ __ __ __ __
TOTAL 56 4.6 69 5.7 67 5.5 73 6.2 33 2.7
PROBLEMS


49

OBSERVATIO 2

DATE: 03-08-2011

PLANT: 1


PROBLEMS M1 % M2 % M3 % M4 % M5 % M6 %
1) Cutting 9 .75 12 1 7 .58 10 .83 13 1.1 20 1.6
2) Open 6 0.5 9 .75 2 .16 7 .58 6 0.5 14 1.3
3) Joint 14 1.3 5 .41 4 .33 17 1.4 15 1.2 16 1.5

U/W 8 .66 40 3.3 21 1.7 22 1.8 24 2 10 .83

5) Breakage 8 .66 __ __ __ __ __ __ 12 1 __ __
6) Coding __ __ __ __ __ __ 20 1.6 __ __ 12 1
TOTAL 45 3.7 66 5.5 34 2.8 76 6.3 70 5.8 72 6
PROBLEMS

M = Machine
Perfect Biscuits packet in % =94.95

50

DATE: 03-07-2011

PLANT: 2


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 2 .16 12 1 15 1.2 21 1.7 24 2
2) Open 1 .08 7 .58 3 .25 8 .66 19 1.5
3) Joint 5 .41 10 .83 8 .66 12 1 17 1.4

4) U/W __ __ 21 1.7 18 1.5 19 1.6 27 2.2

5) Breakage __ __ 12 1 __ __ 9 .75 14 1.3
6) Coding __ __ __ __ 17 1.4 __ __ 27 2.2
TOTAL 8 .66 62 5.1 61 5.1 69 5.7 128 10.6
PROBLEMS


51

DATE: 03-08-2011

PLANT: 3


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 10 .83 12 1 13 1.2 17 1.4 24 2
2) Open 6 0.5 6 0.5 __ __ 7 .58 14 1.3
3) Joint 3 .25 15 1.3 __ __ 18 1.5 24 2

4) U/W 20 1.6 26 2.1 23 1.9 7 .58 12 1

5) Breakage __ __ 14 1.2 __ __ 8 .66 __ __
6) Coding 12 1 __ __ __ __ __ __ __ __
TOTAL 51 4.2 73 6.1 36 3 57 4.7 74 6.2
PROBLEMS


52

OBSERVATIO 3

DATE: 07-08-2011

PLANT: 1


PROBLEMS M1 % M2 % M3 % M4 % M5 % M6 %
1) Cutting 13 1.2 15 1.3 9 .75 19 1.5 24 2 5 .41
2) Open 8 .66 9 .75 4 .33 __ __ 8 .66 8 .66
3) Joint 4 .33 2 .16 16 1.4 9 .75 17 1.4 21 1.7

4) U/W 1 .08 22 1.8 31 2.5 23 1.9 26 2.1 15 1.3

5) Breakage __ __ __ __ 13 1.2 4 .33 12 1 5 .41
6) Coding __ __ __ __ __ __ __ __ __ __ __ __
TOTAL 26 2.1 48 4 73 6.1 55 4.5 87 7.2 54 4.5
PROBLEMS

M = Machine

53

DATE: 07-08-2011

PLANT: 2


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 17 1.4 2 .16 7 .58 __ __ 12 1
2) Open 15 1.2 3 .25 13 1.1 __ __ 5 .41
3) Joint 9 .75 10 .83 18 1.5 __ __ 3 .25

4) U/W 28 2.3 25 2.0 19 1.6 __ __ 8 .66

5) Breakage 12 1 8 .66 10 .83 __ __ __ __
6) Coding __ __ 14 1.1 20 1.6 __ __ __ __
TOTAL 81 6.7 62 5.1 87 7.2 __ __ 28 2.3
PROBLEMS


54

DATE: 07-08-2011

PLANT: 3


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 8 .66 12 1 15 1.2 12 1 17 1.4
2) Open __ __ 8 .66 7 .58 6 .5 8 .66
3) Joint 7 .58 16 1.3 19 1.5 12 1 14 1.3

4) U/W 5 .41 15 1.2 24 2 8 .66 24 2

5) Breakage __ __ 13 1.2 17 1.4 __ __ __ __
6) Coding __ __ __ __ __ __ __ __ __ __
TOTAL 20 1.6 64 5.3 82 6.8 38 3.1 63 5.2
PROBLEMS


55

OBSERVATIO 4

DATE: 11-08-2011

PLANT: 1


PROBLEMS M1 % M2 % M3 % M4 % M5 % M6 %
1) Cutting 8 .66 3 .25 2 .16 2 .16 13 1.3 9 .75
2) Open __ __ 1 .08 4 .33 2 .16 6 0.5 2 .16
3) Joint 9 .08 3 .25 4 .33 7 .58 17 1.4 28 2.3

4) U/W 32 2.6 1 .08 7 .58 6 0.5 23 1.9 5 .41

5) Breakage 1 .08 1 .08 __ __ 1 .08 2 .16 8 .66
6) Coding __ __ __ __ __ __ __ __ __ __ __ __
TOTAL 50 4.1 9 .75 17 1.4 18 1.5 61 5.1 52 4.3
PROBLEMS

M = Machine

56

DATE: 11-08-2011

PLANT: 2


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 6 0.5 15 1.3 7 .58 12 1 20 1.6
2) Open 2 .16 7 .58 3 .25 6 0.5 8 .66
3) Joint 5 .41 11 .91 __ __ 23 1.9 21 1.7
4) U/W 33 2.7 17 1.4 35 2.9 15 1.3 19 1.5
5) Breakage 7 .58 __ __ 12 1 4 .33 8 .66
6) Coding __ __ __ __ __ __ __ __ __ __
TOTAL 53 4.4 50 4.1 57 4.7 60 5 76 6.3
PROBLEMS


57

DATE: 11-08-2011

PLANT: 3


PROBLEMS M1 % M2 % M3 % M4 % M5 %
1) Cutting 8 .66 14 1.2 3 .25 9 .75 15 1.3
2) Open 3 .25 5 .41 __ __ 12 1 6 0.5
3) Joint 17 1.4 16 1.3 18 1.5 5 .41 22 1.8

4) U/W 29 2.4 17 1.4 21 1.7 28 2.3 41 3.4

5) Breakage __ __ 3 .25 1 .08 __ __ 9 .75
6) Coding __ __ __ __ __ __ __ __ __ __
TOTAL 57 4.7 55 4.5 43 3.5 54 4.5 93 7.7
PROBLEMS


58

FINDINGS

High level of defective packets at all machines due to the failure of management in the
followings areas.

Lack of proper training of machine operators.

Many times the size of biscuit is exceeding from the standard size.

There is a scope of considerable reduction in plant process.

The nature of competition has changed significantly in the last couple of years.
In the past, the company has been operating in the protected market. This has
resulted in lot of inefficient practices in machine tools.

So it needs drastic changes in the management practices that affect its
production level.

While maintenance procedure of machines. Company should be sensitive for
the problem of the past.

Excessive burden on plan machines.

59

LIMITATIONS OF STUDY

The study depends on production & operation department & since them were not
willing to reveal any information about their packaging system, their machinery
system so an intended error may have crept it.

Data transparency is restricted to small sample.

The limitation of technique used in analysis cannot be avoided & they are felt well
a study.

Limitation of the study is up to Britannia Industries Ltd.

60

SUGGESTIONS

The organizations give proper knowledge & training for unskilled employees
about their work.

Reduce the excessive burden on plant machines.

Proper maintenance of machines and equipments.

Organization should have to produce according to market demand instead of
the continuous process this will increase the efficiency of machines and
workers.

There should be proper record of wastage. It is good for the company.

Production manager give the proper knowledge about engineering & capacity.

61

CONCLUSION

It was a great experience of Internship at Britannia Industries Ltd. Rudrapur. This In-

plant Internship report is a culmination of all activities done by us at BIL, Rudrapur. It

was a matter of pride for us to be a part of BIL, Rudrapur that is one of India‟s largest

biscuit producing plant. The performance of the unit is very impressive. Through

proper co-ordination, co-operation, communication and motivation of the employees

help this plant to blossom with brightness. We had received all the practical

knowledge about how work performed in plant, how different processes are

undertaken, about working of all the plants, and about different test perform for the

analysis of different product.

Finally we are proud for getting the chance of In-plant Internship in this

beautiful and organized processing plant. We hope that „Britannia‟ always run on the

path of “Success

62

BIBLIOGRAPHY

Plant information by Mehak Singh (Production Manager)

Machines information from Dharamveer Singh(Production Officer)

Annual Report of Britannia Pvt. Ltd.( 2007-08 and 2008-09)

Production and Operation Management by B. S. Goel (BOOK)

www.britanniaindustries.com

www.google.com

www.scribd.com

63

OBSERVATION

DATE:--/--/----
PLANT NO…..

Observation of ….. (no. of biscuit) biscuit packets in each machine of plant.
Total observation in plant is…… (no. of biscuits)

PROBLEMS M1 % M2 % M3 % M4 % M5 % M6 %
1) Cutting
2) Open
3) Joint

4) U/W

5) Breakage
6) Coding
TOTAL
PROBLEMS

M = Machine
Total no of Biscuits packets observed = ……
Total no of problems in Biscuits packets = ……
Total no of perfect Biscuit packet = ……
Perfect Biscuits packet in % = ……
Problems Biscuits packet in % = ……

65

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