The
BISCUIT
MAKING
PROCESS
Project – Gantt Chart
Understanding the Process
Kaizen Implementation
Internal Audit for AIB
AIB Work Implementation
Project Documentation
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Dec ‘17 Jan ‘18 Feb ‘18 Mar ‘18
Reception
PROCESS FLOW
Primary &
Bags Secondary Testing
Silo / Bags
Fat Unloading
Sugar Charging Intermediate
Pre Creaming Wet Preparation Refined Wheat
Ingredient flour
Preparation Charging
Sugar Mixing Refined Wheat
flour
Sheeting /
Moulding
Baking
Packaging
Stock &
Forwarding
MAJOR INGREDIENTS
Refined Wheat Flour
Variety based – Bags/Tankers – Primary & Secondary Testing
Storage Conditions – Sieving - Charging
Sugar
Bags - Storage Conditions – Sieving – Charging - Grinding/Solution making
Fat
Variety based –Hydrogenated vegetable fats - Storage Conditions –
Tankers/Boxes
Additional Usages(Emulsifier preparation etc.,)
MINOR INGREDIENTS
Flavours Properly inspected - Variety based – Accurate Mixture
Emulsifiers Solutions prepared - Variety based – Accurate Mixture
Fortifiers Iron – Vitamin mixture – Whey protein
Raising / Leavening Agents
RECEPTION
Trucks – Inspection of Vehicle – Weighing – Silo / Bags – Sampling methods
for both Silo & Bags – Primary Testing – Secondary Testing – Unloading
INGREDIENT PREPARATION
Wet Preparation
Solutions of Emulsifiers, Seasonings, Sweeteners, Fats etc.,
Flavour Preparation
Proportionate mixing – Precise Solution Mixing Technology
Grinding Sugar Grinding
Sifting Dry ingredients are sifted to remove lumps
MIXING
Variety based – Flow meter controlled
Fermented dough
Batchwise Kneading operation
Tiltable Kneaders with Paddle structure –
Maida, Sugar, Fat from silos
Other ingredients are added manually
Mixing time followed
5050 – Proofing time
Short dough
Continuous Mixing Operation
Precreamer- Liquid ingredients – Cold condition
Continuous mixer – Dry Ingredient from silo & Wet Ingredient from Precreamer
Less Mixing Time – facilitating short dough formation
MIXING
Hard dough
Continuous Mixer
Longer standing time
Other ingredients are added manually
Mixing time followed
SHEETING
Hard dough
Lamination machine
2 Pre Gauge – 2 Gauge – 1 Final Roller
Final – 2mm
5 Sheets into one for uniform mixing
Roller Setup – PLC controlled
Sheets are then cut using rollers with engraved design
Cutter scrap is recycled for sheeting process
Relaxation zone facility is available
MOULDING
Short dough
Moulder machine
Moulding rollers have engraved design
THE BAKING PROCESS
Continuous Baking process
Radiation type of Heat Transfer
Food Grade belt to work at high temperatures
Sensors to assist in proper functioning of the oven
BAKING ZONES
Zone 1&2
Preheating
Zone 3&4
Baking
Zone 5&6
Characteristic Colour Development
COOLING, STACKING
Long belt – Room temperature – Cold air circulation – Residence time –
Adjustable tension – Stacker – Sorting -Automatic/Manual – Recycling
Bins
PACKAGING
Laminate Rolls –HDPE –Packing Machines – Horizontal Form Fill Seal
Packaging–Coding –Packets –Based on Weights –Secondary Packing –
Tertiary Packaging – Sealing
STOCK & FORWARDING
Holding –DQI –Acceptance/Rejection -Forwarding
RECYCLING
Defective Biscuits –Collection –Grinding -Reuse
