Parle G

PRODUCTION LAYOUT

Project on: Parle Glucose (parle G) Parle products

Division: A

Roll. no.: 33

INDEX

INTRODUCTION VARIOUS UNIT OF COMPANY MANUFACTURING PROCESS FLOW CHART PROCESS LAYOUT ( FLOW ) PROCESS LAYOUT ( DESCRIPTION )

Parle Glucose Biscuits

INTRODUCTION

A long time ago, when the British ruled India, a small factory was set up in the suburbs of Mumbai city, to manufacture sweets and toffees. The year was 1929 and the market was dominated by famous international brands that were imported freely. Despite the odds and unequal competition, this company called Parle Products, survived and succeeded, by adhering to high quality and improvising from time to time.

A decade later, in 1939, Parle Products began manufacturing biscuits, in addition to sweets and toffees. Having already established a reputation for quality, the Parle brand name grew in strength with this diversification. Parle Glucose and Parle Monaco were the first brands of biscuits to be introduced, which later went on to become leading names for great taste and quality.

PARLE G - THE EVOLUTION !!!

Parle-G has been a strong household name across India. The great taste, high nutrition, and the international quality, makes Parle-G a winner. No wonder, it's the undisputed leader in the biscuit category for decades. Parle-G is consumed by people of all ages, from the rich to the poor, living in cities & in villages. While some have it for breakfast, for others it is a complete wholesome meal. For some it's the best accompaniment for chai, while for some it's a way of getting charged whenever they are low on energy. Because of this, Parle-G is the world's largest selling brand of biscuits.

IMPORT - EXPORT

Parle biscuits and confectionaries are fast gaining acceptance in international markets, such as, Abu Dhabi, Africa, Dubai, South America and Sri Lanka. Even the more sophisticated markets like USA & Australia, now relish Parle products.

As part of the efforts towards a larger share of the global market, Parle has initiated the process of getting ISO 9000 certification. Many Parle Products have also won Gold, silver and bronze medals at the Monde Selection.

VARIOUS UNIT OF COMPANY

There are five mother units and thirty one contact manufacturing units in India. The main difference between mother units and contact units is that mother units produce more than one product that is PARLE G, MONACO, KRACK JACK, SIXER, HIDE AND SEEK etc. while contact unit manufacture only PARLE G. Mother units are as follows.

Mumbai (Maharashtra)Bhadurdgarh (Haryana)Neemrana (Rajasthan)Banglore and Kolkata

MANUFACTURING PROCESS FLOW CHART

RAW MATERIAL TESTING

MIXING

MOULDING

BAKING

COOLING

PACKING

PROCESS LAYOUT

STEPHAN STEPHAN MIXER MIXER

MOULDING OVEN CURVE PLATE

COOLING CONVYER

CURVE PLATE

STALKING TABLE MULTIPACK MACHINE

BOX SEALING MACHINE TAPPING

DEVIRSION BELT CONVEYOR BELT 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 ( ii ), 500 ( ii ) ],

Salt,

Milk Solids,

Emulsifiers [ 322 or 471 & 481 ( i ) ] and

Dough Conditioners [ 223 ].

Contains Added Flavours (Artificial).* (d - Glucose, Levulose)

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.

FOLLWING ARE THE MACHINERY USED IN MANUFACTURING

STEPHEN MIXER

The Stephan TK Mixer is an ideal component to fully automatically feed the down-stream make-up equipment for biscuits, bread, rolls, buns, cake, sweet goods, cookies and crackers.

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 dough’s 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 sticksSoda crackersRotary cookiesWire-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

1. structure in corrosion-proof; anodised aluminum and Aisi 304 stainless steel 2. satin stainless steel paneling 3. swivel wheels and support feet 4. trays loader with automatic chain feed 5. feeder roller anodised aluminum 6. presser roller in White rubber7. bronze moulder roller with quick change system 8. scraper blade in stainless steel9. pressure adjustment of rubber roller on moulder roller10. scraper blade adjustment11. closed ring outlet belt with tension and centering adjustment 12. belt cleaner blade with extractable drawer 13. product outlet with power driven roller 14. 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.

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. 

BISCUIT BAKING OVEN

Construction: The oven body consists of steel steam tight tunnel with equally divided zones of the radiators. 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.

Insulation:The complete oven will be covered with 10" thick mineral wool insulation from top, bottom and the sides.

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 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. 

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. The packets coming out from the wrapping machine in a minute is programmed in computer and can be changed as per the need.Pack Sizes available:16.5G, 38.5G, 60.5G, 82.5G, 99G, 209G, 313.5G, 418G, 825G

POLY BAGS

Poly bags contain 24 packets of parle g biscuits in one poly bag. 24 packets of biscuits are put into the bag and forwarded 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.