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Packaging of Confectionery and Bakery
Goods
Presented By:-Udit Chawla
Mayur Mali
Anup Chalke
Avinash Singh
Nishikant Lautre
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Introduction:-
Baki g is the tech ique f pr l ge
c ki g f f by ry heat acti g
by c vecti , a t by ra iati ,
rmally i a ve , but als i h t
ashes, r h t st es. It is
primarily use f r the preparati f
brea , cakes, pastries a pies,
tarts, quiches, c kies a crackers.
Such items are s metimes referret as "bake g s," a are s l at
a bakery.
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Classificati f Bake s
Bake g s are maj rly ivi e
i t tw br a categ ries:-
Dry Bakery s (s ft biscuits,
har biscuits, c kies, crackers,
wafers)
M ist Bakery s (cakes,
pastries, brea s, bu s, muffi s etc.)
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Cookies
Cookies are ma e i a wi e variety of styles, usi g a array of
i gre ie ts i clu i g sugars, spices, chocolate, butter, pea ut
butter, uts or rie fruits.
Cookies are most commonly bake until crisp or just long
enough that they remain soft, but some kinds of cookies are notbaked at all.
The softness of the cookie may depend on how long it is
baked.
Unlike cakes, cookies do not use water as the medium f or
cohesion.It may use some a type ofoil in the f orm of butter, egg yolk,
vegetable oil etc. as an agent for forming a bond.
These oils are much more viscous than water and evaporate
freely at much higher temperatures.
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ClassificationofCookies
Drop Cookies
Refrigerator Cookies
MoldedCookies
RolledCookies
ressedCookies
Bar Cookies
Sandwich Cookies
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Cakes
Cake i s a f orm of food, typically a sweet, baked dessert.
Cakes normally contain a combination of flour, sugar, eggs, and
butter or oil, with some varieties also requiring liquid (typically milk
or water) and leavening agents (such as yeast or baking powder).Flavorful ingredients like fruit pures, nuts or extracts are often
added, and numerous substitutions for the primary ingredients are
possible.
Cakes are often filled with fruit preserves or dessert sauces (like
pastry cream), iced with butter cream or other icings, anddecorated with marzipan, piped borders or candied fruit.
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ClassificationofCakes
Cakes are broadly divided into several categories, based primarily
on ingredients and cooking techniques:
Yeast cakes are the oldest, and are very similar to yeast breads.
Such cakes are often very traditional in form.
Cheesecakes, despite their name, aren't really cakes at all.Cheesecakes are in fact custard pies, with a filling made mostly of
some form of cheese.
Sponge cakes are thought to be the first of the non-yeast-based
cakes and rely primarily on trapped air in a protein matrix
(generally of beaten eggs) to provide leavening.
Butter cakes, including the pound cake rely on the combination
of butter, eggs, and sometimes baking powder to provide both lift
and a moist texture.
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Cake Flour
Special cake flour with a high starch-to-gluten ratio is made from
fine-textured, soft, low-protein wheat.
It is strongly bleached, and compared to all-purpose flour, cakeflour tends to result in cakes with a lighter, less dense texture.
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Confectionery
Confectionery is the set offood items that are rich in sugar, any
one or type of which is called a confection.
Confections are generally low in nutritional value but rich in
calories.The word candy (U.S.), sweets (UK) or lolly (Australia) is also
used for the extensive variety that compose confectionery.
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ClassificationofCommonConfectionery oods:-
Chocolates
Candies
Fu
dge
Toffee
Mithai
Chewing um
Jellies
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CandyCandy, specifically sugar candy, is a confection made from a
concentrated solution of sugar in water, to which flavorings and
colorants are added.
Candy is made by dissolving sugar in water or milk to form a
syrup, which is bo
iled
un
til it reaches thed
esired
con
cen
tration
or starts to caramelize.
The type of candy depends on the ingredients and how long
the mixture is boiled.
Candy comes in an endless variety of textures from soft and
chewy to hard and brittle.The final texture of candy depends on the sugar
concentration. As the syrup is heated, it boils, water
evaporates, the sugar concentration increases, and the boiling
point rises.
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Sugar Cooking Stages
Stage Temperature in F Temperature in C Sugar concentration
thread 230-233 F 110-111 C 80%
soft ball (e.g., fudge) 234-240 F 112-115 C 85%
firm ball 244-248 F 118-120 C 87%
hard ball 250-266 F 121-130 C 92%
soft crack 270-290 F 132-143 C 95%
hard crack (e.g.,
toffee)
295-310 F 146-154 C 99%
clear liquid 320 F 160 C 100%
brown liquid
(caramel)338 F 170 C 100%
burnt sugar 350 F 177 C 100%
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Shelf Life
The shelf life of a candy can be anywhere between two weeks to
much more than a year depending upon the storage conditions.
This shelf life may be shortened if the product is not stored in a
cool anddry place.
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General Characteristics of
Confectionery and Baked Goods
Fragility
Loss of Crispiness
Loss of Aroma
Rancidity
Water Activity
Prone to Microbial Activity
Temperature Sensitivity
Low Shelf Life
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Packaging Material
Packaging materials can be broadly divided into 3 categories:-
Primary
Secondary
Transport
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Primary Packs Used for Bakery and
Confectionery oods
Laminates:
Plastic Laminates
Paper LaminatesFoil Laminates
Laminated Tubes
Bubble Wraps
Paper andPaperboard:Folding Cartons
Paper Bags
Composite Cans
Paper Cups
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Secondary Packs Used For Bakery and
Confectionery oods
Plastic:
Pet Jars
Laminate Bags andPouches
Paper andPaperboards:
Folding Cartons
Wrap-around
Paper Bags
Metal:
Metal Cans
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Transport Packs For Bakery and
Confectionery oods
Shrink Wraps
Stretch Wraps
Woven Sacks
Paper Sacks
Folding Cartons
Corrugated Fiber BoardBoxes
WoodenCrates andContainers
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Types ofPackaging Materials Used
Laminates:
B.O.P.P.
B.O.P.P./Met. B.O.P.P.
P.E.T./Met. C.P.P.
P.E.T./Met. P.E.T./Poly
P.E.T./Met. B.O.P.P.
P.E.T./Met. C.P.P.
Met. B.O.P.P./Met. P.E.T./Poly
P.E.T./Al./P.E. (Milk Powder)
(Chips and Wafers)
(Biscuits mostly)
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Contd..
P.E.T./Met. P.E.T./Poly
P.E.T./Poly
P.E.T./Met. B.O.P.P.
P.E.T./Met. C.P.P.
P.E.T/Poly
Met. P.E.T.
H.D.P.E. (Cereals)
Al./Food rade Base Paper/Wax (Chewing Gums)
(Miscellaneous)
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Contd..
Paper Products:
Paper Board
CoatedPaper
lassine Paper
Corrugated Fiber Boards
Metal Products:
Foils
Sheets
Containers
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Co
mparison
C
hart
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Moderate Moisture
Barrier
PE
BOPP
High Moisture Barrier AL FOIL
MET PET & MET BOPP
MET CPP & MET PE
Moderate Gas Barrier PET
5-Layer & 7-Layer PA based PE
High Gas Barrier AL Foil
MET PET, MET BOPP
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SUBSTRATE & THEIR
CHARACTIRISTICS
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Advantage Disadvantage
Good Printability
High Moisture Barrier
Softer and Easily Tear able
Low Density leading to High Yield
Available in:
Plain
Heat Sealable
Metalized
White Opaque
Pearlized
Heat sensitive-exhibits
shrinkage whilst printing
and packing operations.
Low corona retention
period.
B.O.P.P. (Bi-axially Oriented Polypropylene)
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Advantages
AdvantagesDisadvantages
Highest Seal Strength and Hot TackLow oxygen barrier
Highest toughness and drop performance
amongst all sealant.
Low heat resistance
Excellent seal ability and preferred sealant
layer.Low modulus
Available in :
Transparent
Metalized
Easy Tear
Retort grade
3 / 5 / 7 Layers Barrier
P.E.(Polyethylene)
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Excellent printability.
Oxygen barrier.
High gloss.
High heat resistant.
Available in metalized, PVDC
coated, SiOx and alumina coated
for enhanced barrier.
Corona & chemically treated for
better anchorage.
Not suitable for moisture
sensitive products in bare form.
Too stiff to be used for softer
and crumple-less packs for feel-
good effect.
High density leading to low
yield.
P.E.T.(Polyethylene Terephthalate)
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Advantages Disadvantages
High Seal Strength High Clarity
Higher Stiffness than PE
Good Hot-Tack and Faster cooling time suitable for high
speed of candies packing. High Heat resistance
Available in:
Transparent
Metalized
White Opaque
Retort grade
Comparatively lowHot-Tack and low Dart
impact than PE
restricting its application
in many packaging
areas.
C.P.P.
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Advantages Disadvantages
Highest gas, vapor and light
barrier
Poor pin-holes and crack
resistance
Possesses dead fold Chemically reactive withacidic products
Good surface appearance
Moderate printability
Aluminum Foil
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Advantages Disadvantages
High Bulk
High Stiffness
Dead Fold
Available in
Poster
Map litho
Chromo
Glassine
Kraft
Tissue
Chromo is the best printable paper
Poor Barrier
Poor Inter-Layer
Bonding
Moisture Absorbent causing
curling & de-lamination problemsat times
Paper
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Advantages Disadvantages
Comparatively high Oxygen
Barrier and Moisture Barrier
than bare film.
Metallic Finish
Poor inter-layer bond
strength than bare substrate
on account of poor metal
adhesion.
Opaque Packaging
MET. P.E.T., MET. B.O.P.P., MET. C.P.P.
MET PE
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Package Material Testing
Testing and Its Significance
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Significance Of:-
Grammage Test:-
Since most of the polymer film is bought and sold in
accordance with its weight, this property hassignificance both to consumer and producer in defining
price.
Most physical properties such as Thickness and Bulk
are evaluated and specified in accordance withparticular grammage involved.
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Significance Of:-
Thickness and Density Test:-
Thickness is very important property as it affects
apparent density, air resistance, rigidity, etc.
Uniformity in thickness is important for most of
requirements. Apparent density influences almost all
physical property as well as printing.
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Significance Of:-
Tensile Strength Test:-
Tensile strength is indicative of the durability and
serviceability of many materials which are subjected
todirect tensile stresses.
It indicates potential resistance to breaking when
subjected to strains during travel from roll through the
press and labeling machine.
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Significance Of:-
Tear strength Test:-It is primarily a property of inner structure of paper. In plastics, it is a
combination of shear and elastic properties. It can influence
processing characteristic.
Unit : gm/micron
Significance : Higher the tear strength value, greater the difficulty to
tear the film. This data is useful in designing the film for laminate /
required application. E.g. - Chocolate packs need lower tear strength
for easy tear.
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Significance Of:-
Haze Test:-
This is an optical property indicating amount of haziness in
film.
Light that is scattered upon passing through a film can
produce hazy field when objects are viewed through material.
This property is affected by surface or internal defect which
can arise while handling or processing.
This property can be useful f or Quality Control and
Specification purposes.
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Contd..
Significance:-
Film clarity is a highly desirable feature for most clear
packaging and label applications.
It tends to symbolize quality and contributes to the positive
visual display of the product.
Compared to other flexible plastic films, clear OPP has one of
the lowest haze values, generally less than 3%.
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Test principles
As represented in the figure , a unidirectional light beam is directed
onto the film specimen. After it enters an integrating sphere, a photo
detector measures the total light transmitted by the film and the
amount of transmitted light that is scattered more than 2.5. Haze is
the percentage of total transmitted light that is scattered by more
than 2.5.
Contd..
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Significance Of:-
Coefficient Of Friction Test:-
Co efficient of Friction, a surface phenomena of
plastic films, is related to slip properties that are of
wide interest in packaging applications.
This test yield empirical data for control purposes in
film prod
uction
.Correlations of test results with actual performance
on machine can be established.
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Contd..
Slip properties are generated by additives which exude to the
surface which makes it slippery.
Manufacturing process and additives used as well as rate of
loading and speed affects the value.
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Significance Of:-
Melt Flow Index:-It is defined as the amount of polymeric mass flow
through narrow orifice when it is extruded at a
specified load at a specific temperature as per
standard.
Heat seal Strength Test:-To understand the heat sealing range to polymers.
This helps in selecting a polymer with optimumsealing temp.
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Significance Of:-
WATER VAPOR TRANSMISSION RATE:
WVTR (water vap
o
r tran
smission
rate) is the stead
y state rate at which
water vapor permeates through a film at specified conditions of
temperature and relative humidity.
Values : g/m2/24 hr in metric (or SI) units.
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Contd..
Significance :
WVTR is the standard measurement by which films are compared
for their ability to resist moisture transmission.
Lower values indicate better moisture protection.
Only values reported at the same temperature and humidity can
be compared, because transmission rates are affected by both of
these parameters.
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WVTR TableMaterial WVTR, g/m2, 24 hr. 38C & 90% RH.
Flat Folded Crumpled Gelboflex
MetP
ET (12) 0.9
1.7
3.4 18
Met PET / LDPE (50) 0.5 0.6 0.7 0.6
2-sides PVDC coated
PET
4.2 3.7 5.9 4.8
2-sides PVDC coated
PET/LDPE
2.9 3.6 3.3 3.1
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Significance Of:-
Oxygen Transmission Rate:-
OTR (oxygen transmission rate) is the steady state rate
at which oxygen gas permeates through a film at
specified conditions oftemperature and relative
humidity.
Value : cc/m2/24 hr in metric (or SI) units.
Standard test conditions are 73F (23C) and 0% RH.
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Contd..
Significance :
The air we breathe is about 21% oxygen and79% nitrogen, with
very small concentrations ofother gases like carbondioxide and
argon.
Essential to human and animal life, oxygen gas is also a reactive
compound that is a key player in food spoilage.
Most of the chemical and biological reactions that create rancid
oils, molds, and flavor changes require oxygen inorder tooccur.
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Contd..
Two methods for reducing product exposure to oxygen via flexiblepackaging:
MAP (modified atmosphere packaging) is a process for replacing
the air in the headspace of a package with another gas before the
final seal is made.
This is also called gas flushing.
The most common replacement gases are nitrogen or
nitrogen/carbon dioxide mixtures.
The shelf lives of potato chips, dried fruits, nuts, and shredded
cheese are commonly extended by this packaging method.
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Contd..
Vacuum packaging is where the atmosphere is drawnout and
eliminated, rather than being replaced by another gas.
This vacuum forces the flexible material toconform to the
product shape.
Juices (fresh and processed) and cheeses are commonly
packaged this way.
Once air has been replacedor eliminated from the package,
there must be anadequate oxygen barrier andseal integrity to
keep a low oxygen concentration inside the pack.
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Significance Of:-Opacity:-
Opacity represents a substrate's light blocking
ability.
It is primarily used as a property of paper and
predicts the relative visibility on one side of the
paper of the images that exist on the other side.
White opaque films are replacing paper in some
applications, therefore one needs to measure
opacity for some white films.
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Significance Of:-
Gloss Test:-Gloss is a measurement ofthe relative luster or shininess of a
film surface.
The incident light beam strikes the film surface at a 20, 60 & 85
degree angle from the perpendicular.
A sensor measures the amount of light reflected by the film at
a mirror image angle.
The gloss value is the ratioof this reflected light to incident
light and is reported ingloss units.
Theoretically, the range of the gloss scale is 0 to 100.
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Contd..
Significance:
It indicates the degree of pleasing sparkle on the product
surface.Higher the gloss higher is the degree of shining of the product.
Shininess, brilliance, and sparkle are properties related to a
film's glo
ss value.They can be valuable appearance attributes for packages,
labels, or graphic arts items.
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What affects film gloss..?
Gloss is primarily determined by material selection and surface
smoothness, which are defined during product and process
development.
Day-to-day process variations will have an insignificant effect on
gloss.
Transparent films have two reflecting surfaces. Although rare, this
can lead to gloss values that exceed 100.
Contd..
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Packaging Laws and
Regulations
The Link Between FoodPackaging and
Consumer Protection
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Overview
The link between food packaging and consumer protection is
of high significance.
A package is a vehicle of safety and achieves the objective of
delivering safe, wholesome, nutritious food to the consumer.
To safeguard the interests of the consumer and the society at
large, Packaging Laws and Regulations have been introduced by
the Government.
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The Packaging Laws and Regulations for food
products are mainly covered under:
The Standards of Weights and Measures Act, 1976 and the
Standards of Weights and Measures (Packaged Commodities)
Rules, 1977 (SWMA).
The Prevention of Food Adulteration Act, 1954 and the
Prevention of Food Adulteration Rules, 1955 and its first
amendment, 2003 (PFA).
The Fruit Products Order, 1955 (FPO)
The Meat Food Products Order, 1973 (MFPO)
The Edible Oil Packaging Order, 1998
The Agmark Rules
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The Standards of Weights and
Measures Act
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The Act also specifies the base units for:
Length Metre
Mass Kilogram
Time Second
Electric Current Ampere
Thermodynamic Temperature Kelvin
Luminous Intensity Candela
Base Unit of Numeration International form of Indian
numerals.
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DeclarationonPackagedCommodities for
Interstate Trade or Commerce:
Identity of the commodity in the package.
Net quantity, in terms of the standard unit of weight or
measure, of the commodity in the package.
Where the commodity is packagedor sold by number, the
accurate number of commodity containedin the package.
The unit sale price of the commodity in the package.
The sale price of the package.
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Label Declarations:
Then
ame and
add
resso
f the man
ufacturero
r where themanufacturer is not the packer, the name and address of the
manufacturer andpacker.
The commonor generic names of the commodity containedin
the package.
The net quantity in terms of the standard unit of weight or
measure, of the commodity contained in the package or where the
commodity is packedor sold by number, the number of commodity
contained in the package.
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The month and year in which the commodity is manufactured
or pre-packed. (Provided that for packages containing food
articles, the provisions of the Preventionof Food Adulteration
Act (PFA), 1954 (37of 1954) and the rules made there under
shall apply).
The retail price of the package.
The retail sale price of the package.
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Commodities to be Packed in Specified
Quantities (StandardPackages)
as per The Third Schedule of SWMA Rules
Commodities Quantities In which to be
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Commodities Quantities In which to be
packed
Biscuits 25g, 50g, 75g, 100g, 150g, 200g,250g, 300g and thereafter in
multiples of 100g up to 1 kg
Bread including brown bread but
excluding bun
100g and thereafter in multiples of
100g
Cereals 100g, 200g, 500g, 1 kg, 2 kg, 5 kg
and thereafter in multiples of 5 kg
Aerated soft drinks and
non- alcoholic drinks
100ml, 150ml, 200ml, 250ml,
300ml, 330ml (in cans only),
beverages 500ml, 750ml, 1 litre,
1.5 litre, 2 litre, 3 litre, 4 litre, and 5
litre
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Maximum Permissible Error in Relation to
Quantity Contained in Individual Package
as per the First Schedule of SWMA Rules
Description of Commodity Quantity Declared Maximum
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Permissible
Error
B
iscuits i. Up to
and
equal to
500gii. Above 500g
7
.0%6.0%
Bread i. Up to and equal to 400g
ii. Above 400g up to and
equal to800g
iii. Above 800g up to andequal to 1200g
8.0%
6.0%
4.0%
Provisions sold in poly bags
or plastic bags and
powdered commodities(such as, dry fruits, seeds and
other
commodities (such as, sugar gur,
khandsari and the like)
i. Up to and equal to 100g
ii. Above 100g up to and
equal to 500giii. Above 500g up to and
equal to 1kg
iv. Above 1kg
3.0%
2.0%
1.5%
0.75%
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Symbols for Unit
Kilogram Kg
Gram g
Milligram mg
Litre l
Millilitre ml
Metre mCentimetre cm
Millimetre mm
Square metre m2
Square centimetre cm2
Cubic metre m3
Cubic centimetre cm3
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As per the Act a food is deemed to be adulterated:
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As per the Act, a food is deemed to be adulterated:
(a) If the article sold by a vendor is not of the nature, substance or
quality demanded by the purchaser and is to his prejudice, or is not ofthe nature, substance or quality which it purports or is represented to
be.
(b) If the article contains any other substance, which affects, or if the
article is so processed as to affect, injuriously the nature, substance or
quality thereof.
(c) If any inferior or cheaper substance has been substituted wholly or in
part for the article so as to affect injuriously the nature, substance orquality thereof.
Contd
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Contd
d) If any constituent of the article has beenwholly or in part abstracted
so as toaffect injuriously the nature, substance or quality thereof.
(e) If the article had been prepared, packedor kept under insanitary
conditions whereby it has become contaminatedor injurious to health.
(f) If the article consists wholly or in part of any filthy, putrid, rotten,
decomposedor diseased animal or vegetable substance or is insect-
infestedor is otherwise unfit for human consumption.
(g) If the article contains any poisonous or other ingredient which
renders it injurious to health.
(h) If the container of the article is composed, whether wholly or in part,
of any poisonous or deleterious substance which renders its contents
injurious to health.
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A utensil or container made of the following materials or metals,
when used in the preparation, packaging and storing of food shall
be deemed to render it unfit for human consumption:
Contai
ners which are rusty Enamelled containers which have become chipped and rusty
Copper or brass containers which are not properly tinned
Containers made of aluminium not conforming in chemical
composition to IS:20 Specification for cast aluminium and
aluminium alloy for utensils or IS:21 specification for wroughtaluminium and aluminium alloy for utensils
container made of plastic materials not conforming to the
Indian Standards specifications.
Packaging and Storage Requirements
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Fruit Products Order (FPO)
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Fruit Products Order is concerned with fruit and vegetable
products including synthetic beverages, syrups, sharbats and vinegar.
Objective of this law is mainly to regulate the quality and hygiene of
these products.
All labels should have the approval of the authorities concerned, and
carry the license number allotted.
FPO also prohibits use of any statement, designor device, which is
false or misleading concerning the fruit product.
Synthetic products associated with fruits and vegetables should clearly
be markedSYNTHETIC.