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BYBYASHAASHAAARTI NIMANIAARTI NIMANIMINACSHIMINACSHILALITHA SUDHALALITHA SUDHASANTANA PRIYADARSHNISANTANA PRIYADARSHNISANGAMITRASANGAMITRASAHITYASAHITYAASHNAASHNA

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INTRODUCTION

• We undertook this internship programmed training at Mega foods Pvt.Ltd.

• The training was for a period of 4 weeks.• We were groomed to accept various

challenges of industry and learnt to keep up the time limit. This enabled us to correlate theory and practical.

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INFRASTRUCTURE• The factory is located on a site of about 26500 square ft.• The unit is located in a well-developed industrial estate which

is close to the city.• The man power employed include professionally qualified

people heading each department.• Reverse osmosis plant is also provided for the safe usage of

water.

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Mission statement “TO PRODUCE QUALITY FOOD PRODUCTS THAT ADD

VALUE TO OUR CONSUMER,BUYERS,DEALERS AND EMPLOYEES AND THEREBY BECOME THE MOST

REPUTED AND PROFITABLE COMPANY”

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PROMOTERS

• THE CHIEF PROMOTER OF THIS COMPANY IS MR.AMIT C VAISHNAV, A MECHANICAL ENGINEER AND A MEMBER OF FOOD SCIENTISTS AND TECHNOLOGISTS(MYSORE)

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PRODUCTS

• JAMS• CHIILY SAUCES• SOYA SAUCE• READY TO EAT PRODUCTS• SQUASH• FRUIT SYRUP• TOMATO SAUCE/KETCHUP

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LAB ANALYSIS• Lab analysis consists of the various tests done in order to

prepare a stable and consistent food product.

• There are various apparatus that are used for eg:pH meter ,etc.

• The following tests are done in this food industry:

1)BRIX TEST 2)ACIDITY OF PULP 3)pH OF PULP/JUICE

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This test is done in order to asses the amount of dissolved salts present inthe given fruit extract.

The instrument used to perform this test is knownas the refractometer.

The refractometer used for juices ranges between 0-50% and that of jams is 40-85%.

Acidity test is done in order to determine the amount of acid added to the fruit juice or pulp and thereby determine the amount of extra acid that has to added.

The calculation of acidity can be done in 2 ways:-

1)Acid-base titration

2)pH method

The pH method is done with a pH meter.

The pH is done to check and hence maintain the acidity of the given fruit pulp or juice.

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COMPANY HYGIENEOne of the most essential factors to be maintained in a food

industry is hygiene. At Mega foods the following measures are followed:-

1)On entering the production area one must disinfect their hands using a sanitizer and the workers should wash their legs.

2)People who are associated with preparing the food products should not wear footwear.

3)All workers are to wear lab coats and also cover their head with a head cap to prevent hair from falling into anything.

4)All machines should be washed and cleaned before use.

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Puree/ pulp preparation for jams and sauces

Receipt of fruits/vegetables

Incoming inspection

Storage

Send back to supplier

100% segregation

fruit?/vegetables washing

Fruit cutting/preparation Processing Cleaned cans

Pulp storage in cansA

Ok

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ALAB analysis, menu generationand issue of RM as batch cardTransfer ingredients to kettle,Process and finish product

Lab inspection Move to reprocess area

Transfer to SS vessel scrap

Fitting operation

Seating

Labeling

Packing, storage and dispatch

LAB inspection

Stored for reprocess

B

C

D

E

Not Ok

Not Ok

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MANUFACTURING PROCESS OF JAM

Tested pulp( brix test and acidity) is added to kettle and boiled

Addition of sugar and pectin with continuous stirring and boiling

Addition of citric acid

LAB test for final standards and end test

Addition of coloring agents and flavoring agents.Sent for filling and packing

All jams are prepared in similar manner with slight variations.

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MANUFACTURING OF DIET FRUIT JAM

Tested pulp (brix test and acidity)Is added to kettle and boiled.

Sorbitol+ diet+ pectin+ calcium chloride+ aspartame

Addition of citric acid

LAB test for final standards and end test

Addition of coloring agent and flavoring agent.Sent for filling and packing.

DIET FRUIT JAM

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JAMS• Mixed fruit jam• Pineapple jam• Grape jam• Mango jam• Strawberry jam• Raspberry jam

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TESTS CONDUCTED TO CHECK JAMS READINESS

• Sheet test

• Plate test

• Cut test

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INGREDIENTS Orange juice (Unpeeled orange is cut into four pieces and boiled in water

and as soon as the juice oozes into the water, extract is filtered), sodium benzoate, citric acid, sugar, pectin, coloring and flavoring agent

MANUFACTURE OF ORANGE MARMALADE boiled

tested for acidity and Brix

Orange juice+ sodium benzoate Add sugar and pectin

Add citric acidAdd coloring and flavoring agent

Sent for filling and packing

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Sauce / ketchups

• They are mainly manufactured according to demand

• They are made from puree or paste

• The sauce manufactured is Tomato sauce Tomato ketchup Chilly sauce Soya sauce

                                                                                   

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Ingredients Tomato puree (cooked without water and passed through a pulpier), sugar, salt, sodium

benzoate, sodium saccharine, red chilly powder, turmeric powder, cinnamon oil, clove oil, gum and water

Manufacture of tomato puree

tomato puree+ sodium benzoate+Red chilly pdr + turmeric pdr +

1 part of sugar

Add sugar &gumWith continuous

stirring

Put in colloid mill

Add acetic acid, corn flour,Cinnamon oil, clove oil

Sent for fillingAnd packing

tested for acidity ,brix and salt boiled

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Tomato ketchup

Ingredients

Tomato puree (cooked without water and passed through a pulpier), sugar, salt, sodium benzoate, ginger-garlic paste, onion, red chilly powder, ginger oil, cinnamon oil, corn flour, gum and water.

Manufacture of tomato ketchup

Tomato puree+ ginger garlic paste+ sodium benzoate+

Onion+ red chilly pdr

Heating followed by addition Of corn flour

Add cinnamon oil, sugar,Ginger oil

Sent for filling andpacking

passed through colloid mill

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CHILY SAUCE

INGREDIENTS Chilly paste, potato paste, water, gum, mustard solution, salt, jaggery, ginger-garlic

paste, sodium benzoate, turmeric, MSG.

Manufacture of chilly sauce

Add potato paste+ mustard sol

Add jaggery+ salt+ sodiumBenzoate+ turmeric pdr+

MSG

Sent for fillingAnd

packingFinal lab test

Chilly paste

tested for salt , acidity, brix

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Soya sauce

INGREDIENTS Soya extract (Soya beans are cleaned, socked and cooked under pressure till they

become soft. It is then crushed and it is sprayed in tray. It is inoculated with species of mould-Aspergillus Niger and incubated in a sterile room at 37 degree Celsius for 76-96 hours and left for 6 months for fermentation) salt, gum, water, jaggery, caramel, color mix, ginger-garlic paste, sodium benzoate and corn flour.

Manufacture of Soya sauce

Soya extract+ jaggery sol+ salt+ caramel+ MSG+

Sodium benzoateBoiled and checked

For brix

Sent for fillingAnd packing

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INGREDIENTS

• Fruit pulp • Sugar• Citric acid• Sodium benzoate• HS gum

• Potassium sorbate• Sodium citrate• Water• Color mix• Flavor

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Addition of coloring and flavoring agent

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INGREDIENTS

• Fruit pulp• Aspartame• Sorbitol• Citric acid• HS Gum

• Potassium sorbate• Sodium citrate• Water• Color mix• flavor

•Sodium benzoate

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Addition of coloring and flavoring agent

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Pod type of capsicum, medium to large size chili

pepper

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PREPARED SYNTHETICALLY

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WASHING

the bottles are soaked in cold water

Soak in soap water

washed in ordinary water then with hot water mixed with sodium benzoate.

PNEUMATIC FILLING

SHRINK TUNNEL

BOTTLE STERILIZER

POUCH PACKING

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FILLING

the filling machine is first washed with 0.01% sodium benzoate + hot water

the bottles are filled

they are sealed with zinc seals and closed with suitable caps

allowed to cool

counted and recorded

STEAMING

after washing they are sent to bottle sterilizer machine.

flow of water

them steamed to sterilize bottles.

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PACKING

wiped

labels

shrink cover and sent through the shrink tunnel

carton box

100g, 200g, 500g and 4kg containers

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IN FACTORY

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