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 sticks
Soda crackers
Rotary cookies
Wire-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 rubber
7. bronze moulder roller with quick change system
8. scraper blade in stainless steel
9. pressure adjustment of rubber roller on moulder roller
10. scraper blade adjustment
11. 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.