Description
Manufacturing of Parle Biscuits
PARLE
About the Company A cream coloured yellow stripped wrapper with a cute baby photo containing 10 - 12 biscuits with the company’s name printed in Red and you know these are Parle G biscuits. Times changed, variety of biscuits did come and go but nothing has changed with these biscuits. Yes, the size of their packing has definitely changed but for the consumers good as these is money savers pack. The Parle name conjures up fond memories across the length and breadth of the country. After all, since 1929, the people of India have been growing up on Parle biscuits & sweets. Initially 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 onto become leading names for great taste and quality. For around 75 years, Parle have been manufacturing quality biscuits and confectionery products. Over the years Parle has grown to become a multimillion-dollar company with many of the products as market leaders in their category. The recent introduction of Hide & Seek chocolate chip biscuits is a product of innovation and caters to a new taste, being India’s first ever chocolate-chip biscuits. 1
All Parle products are manufactured under most hygienic conditions. Great care is exercised in the selection and quality control of raw material and standards ensured at every stage of the manufacturing process. Parle Products has 4 manufacturing units for biscuits and confectionaries at Mumbai, Haryana, Rajasthan and Karnataka. It also has 14 manufacturing units for biscuits & 5 manufacturing units for confectioneries; on contract. All these factories are located at strategic locations, so as to ensure a constant output & easy
distribution. Today, Parle enjoys a 40% share of the total biscuit market and a 15% share of the total confectionary market, in India. The marketing mix of Parle for this project has been studied from the point of view of Parle biscuits; mainly Parle-G and Parle hide & seek.
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 incities & in villages. While some have it for breakfast, for others it is acomplete 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 . Launched in the year 1939, it was one of the first brands of ParleProducts. It was called Parle Glucose Biscuits mainly to cue that it was aglucose biscuit. It was manufactured at the Mumbai factory, Vile Parle andsold in units of half and quarter pound packs. The incredible demand led Parle to introduce the brand in specialbranded packs and in larger festive tin packs. By the year 1949, ParleGlucose biscuits were available not just in Mumbai but also across thestate. It was also sold in parts of North India. The early 50s produced over150 tones of biscuits produced in the Mumbai factory. Looking at thesuccess of Parle-G, a lot of other me-too brands were introduced in themarket. And these brands had names that were similar to Parle GlucoseBiscuits so that if not by anything else, the consumer would err in pickingthe brand. This forced Parle to change the name from Parle Glucose Biscuitsto Parle-G. Originally packed in the wax paper pack, today it is available in acontemporary, premium BOPP pack with attractive side fins. The newairtight pack helps to keep the biscuits fresh and tastier for a longer period.Parle-G was the only biscuit brand that was always in short supply. It was heading towards becoming an all-time great brand of biscuit. ParleGstarted being advertised in the 80's. It was advertised mainly through pressads. The communication spoke about the basic benefits of energy andnutrition. In 1989, Parle-G released its Dadaji commercial, which went on tobecome one of the most popular commercials for Parle-G. The commercial was run for a period of 6 years.Parle-G grew bigger by the minute. Be it the packs sold, the areascovered or the number of consumers. It became a part of the daily lives of many Indians. It wasn't a biscuit any more. It had become an
icon.The nextlevel of communication associated the brand with the positive values of lifelike honesty,sharing and caring. In the year 1997,Parle-G sponsored the tele-serial of the Indiansuperhero, Shaktimaan that went on to become a huge success. Thepersonality of the superhero matched the overall superb benefits of thebrand. Parle extended this association with Shaktimaan and gave away a lotof merchandise of Shaktimaan, which was supported by POS and presscommunication. The children just could not get enough of Parle-G and Shaktimaan. In the year 2002, it was decided to bring the brand closer to the child who is a major consumer. A national level promo - `Parle-G Mera SapnaSach Hoga' was run for a period of 6 months. The promo was all aboutfulfilling the dreams of children. There were over 5 lakh responses and of that, over 300 dreams were fulfilled.Dreams that were fulfilled ranged from trips to Disneyland at Paris &Singapore; free ride on a chartered plane; 20 scholarships worth Rs 50,000;a special cricket coaching etc.The year 2002 will go down as a special year in Parle-G's advertisinghistory. A year that saw the birth of G-Man - a new ambassador for Parle-G.Not just a hero but also a superhero that saves the entire world, especiallychildren from all the evil forces. A campaign that is not just new to theaudiences but one that involves a completely new way of execution that isloved by children all over the world – Animation To make the brand much more interesting and exciting with children, it was decided to launch a premium version of Parle-G called Parle-G Magix in the year 2002. Parle-G Magix is available in two exciting tastes -‘Cocoh’and‘Cashew’. The year 2002 also witnessed the launch of Parle-G Milk Shakti,which has the nourishing combination of milk and honey, especially launched for the southern market.
Parle Legacy
MILESTONES - THE DECADES OF PROGRESS
? 1929 ? 1939 The first year of operation. Their only assets were hard work and hope. Ten years of determined effort brought results. Things began to take shape. And they tried even harder.
? 1949 ? 1974
The formative years were over. They had come of age. It was the first evidence of Parle as it is today.
Product strategy Product Levels 1) Core benefit- the core benefit of biscuits is to satisfy hunger of the consumer 2) Basic product- in the second level, the basic product is biscuits. 3) Expected product- the consumers expect the product to have a good taste andalso give nutrition. 4) Augmented product- parle biscuits increase a person’s energy levels. This is notalways expected by the consumers and hence exceeds customer’s expectations.5) Potential product- in the future parle could come up with different products suchas a snack which could be a combo of chocolate and biscuit. Classification of products 1) Based on tangibility- Parle biscuits are tangible, i.e. one can see and touch them. 2) Based on functional life- Parle biscuits are consumables since biscuits form apart of food and have a short life. 3) Based on price and quality- most of Parle biscuits such as Parle-G, Monaco,Krackjack are mass products but a few Parle biscuits such as Parle hide and seekand Milano are premium or prestige products. 4) Based on utility- Parle biscuits are convenience goods. They are staples sincethey are bought by consumers regularly. Also they are partly impulse products
Brand The Parle Biscuit brands, such as, Parle-G, Monaco and Krackjack enjoy astrong imagery and appeal amongst consumers. Be it a big city or a remotevillage of India, the Parle name symbolizes quality, health and great
taste. And yet, this reputation has been built, by constantly innovating and catering to newtastes. This can be seen by the success of new brands, such as, Hide & Seek andHide & Seek Milano. • Brand name strategyParle follows company brand name strategy , since all its products are namedusing the company’s name as a prefix such as Parle-G, Parle- Monaco, Parlehide&seek, Parle digestive Marie, etc. •Brand strategy decision: Old Brand name New Parle follows both line extension and brand extension for its products. For a product like Parle-G it followed line extension with the introduction of Parle-G milk Shakti and Parle-G magix which has 2 flavors- choco and cashew .For Parle Monaco too it followed line extension when a new favor Monaco jeera was introduced. Similarly when it introduces any new product in the biscuit category, it follows line extension.Initially Parle used to produce only confectionaries. Parle followed brandextension with the introduction of products in the biscuits and snacks category.In this way, by concentrating on consumer tastes and preferences andemphasizing Research & Development, the Parle brand grows from strength tostrength.
Various units of The 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 ? Hyderabad (Andhra Pradesh)
Manufacturing process flow chart
Manufacturing of Product
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 Baking powder) Milk solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough conditioners (E 223) and contains added flavours.
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.
Wastage
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.
Loose Biscuits
On the stalking table one to two rows of baked biscuits are kept aside for selling it as loose biscuits. They are normally assumed to be damaged biscuits but they are not damaged or broken but company keep such loose packets of biscuits to sell it to the local people for marginal rate of 33 Rs / kg.
? Stephen Mixer
The FOLLWING ARE THE MACHINERY USED IN MANUFACTURING 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 advantages are compelling: High volume output results from the short kneading time and fast ingredient charging: 1000 kg/h to 6000 kg/h depending on the model. Totally unassisted automatic discharge combines with predividing of the dough into approximately 15 kg. Pieces, is the basis for a fully automatic operation without the need for any full-time operator. Dosing of flour, water, yeast, salt, shortening and other nutrients. In a few seconds, all ingredients are homogeneously mixed. Then, as the dough begins
to develop, the Stephan energy meter control will ensure each dough is finished to the same development The Stephan Mixer is most economical with: No-time dough formula Straight dough Liquid broth (yeast slurry) system Flour fermented liquid sponge system. From batch to batch, the doughs will be consistently uniform: "Process Control" Compact construction, no building preparation necessary, almost service-free day-toThe direct drive design allows the kneading element to be fastened directly onto motor no coupling or power transmission. Easy to clean. Only solid stainless steel construction. Quiet operation, less vibration. Count on a better result. In these competitive times, good kneading is not enough. For a profitable operation, you need a short process time and an exact control on input energy which allows you to mix each dough to the same development curve. A short amortization of the capital investment occurs due to an increase in productivity - more finished product from same amount of flour - and due to a perception of better quality in the areas of longer shelf life, "a delicate crumb", softer crumb structure, higher volume and increased flavor. day operation. shaft. There is
The process control is simple and reliable. The processes of ingredient loading, mixing and dough discharge are
controlled by each program. Depending on the ingredient loading system design, the recipe change needs no change of program. However, if the dosing system can not be adjusted independently, then a different program can be used for each recipe. The ingredient loading system should be designed to allow each scaled ingredient to be weighed during the mixing time of each previous batch. With this pre-scaling or staging of ingredients, all ingredients are ready to be charged at the same time. This system design will save time and thereby increase output. This control system would operate the entire loading, batching, mixing, discharging and dough conveying system. This would include the logic for accurate scaling of ingredients. Here's how the Stephan Mixer works.
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.
Stephen Mixer
The Quality Commitment
Parle Products has one factory at Mumbai that m a n u f a c t u r e s b i s c u i t s & confectioneries while another f a c t o r y a t B a h a d u r g a r h , i n H a r y a n a m a n u f a c t u r e s biscuits. Apart from this, Parle has manufacturing facilities at Neemrana, in Rajasthanand at Bangalore in Karnataka. The factories at Bahadurgarh and Neemrana are the largest such manufacturing facilites in India. Parle Products also has 14 manufacturingunits for biscuits & 5 manufacturing units for confectioneries, on contract.All these factories are located at strategic locations, so as to ensure a constant output& e a s y distribution. Each factory has state -of-the-art machinery with a u t o m a t i c printing & packaging facilities.All Parle products are manufactured under the most hygienic conditions. Great care isexercised in the selection & quality control of raw materials, packaging materials & rigid quality standards are ensured at every stage of the manufacturing process
The major products offered by Parle-G industries are the following: 1.Brand Name: GoodDay and Marrie from Parle Gare stable and are the most established brand in biscuit segment being equated for biscuits for long time. Now the brand has taken a dent though among the present generation with competitors coming up with more powerful advertising campaigns and offering more variety. 2.Styling & Packaging: P a r l e G o f f e r i n g s h a v e t h e i n n o v a t i v e d e s i g n s a n d packaging as compared to what is offered by the competitors. As it's a variety seeking product the styling and packaging helps in getting more customers. 3. Quality: ParleG name is associated with quality. The offerings from ParleG are of best quality when it comes to taste and hygiene. Under it's mission statement "eat healthy think better"
doc_298373563.docx
Manufacturing of Parle Biscuits
PARLE
About the Company A cream coloured yellow stripped wrapper with a cute baby photo containing 10 - 12 biscuits with the company’s name printed in Red and you know these are Parle G biscuits. Times changed, variety of biscuits did come and go but nothing has changed with these biscuits. Yes, the size of their packing has definitely changed but for the consumers good as these is money savers pack. The Parle name conjures up fond memories across the length and breadth of the country. After all, since 1929, the people of India have been growing up on Parle biscuits & sweets. Initially 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 onto become leading names for great taste and quality. For around 75 years, Parle have been manufacturing quality biscuits and confectionery products. Over the years Parle has grown to become a multimillion-dollar company with many of the products as market leaders in their category. The recent introduction of Hide & Seek chocolate chip biscuits is a product of innovation and caters to a new taste, being India’s first ever chocolate-chip biscuits. 1
All Parle products are manufactured under most hygienic conditions. Great care is exercised in the selection and quality control of raw material and standards ensured at every stage of the manufacturing process. Parle Products has 4 manufacturing units for biscuits and confectionaries at Mumbai, Haryana, Rajasthan and Karnataka. It also has 14 manufacturing units for biscuits & 5 manufacturing units for confectioneries; on contract. All these factories are located at strategic locations, so as to ensure a constant output & easy
distribution. Today, Parle enjoys a 40% share of the total biscuit market and a 15% share of the total confectionary market, in India. The marketing mix of Parle for this project has been studied from the point of view of Parle biscuits; mainly Parle-G and Parle hide & seek.
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 incities & in villages. While some have it for breakfast, for others it is acomplete 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 . Launched in the year 1939, it was one of the first brands of ParleProducts. It was called Parle Glucose Biscuits mainly to cue that it was aglucose biscuit. It was manufactured at the Mumbai factory, Vile Parle andsold in units of half and quarter pound packs. The incredible demand led Parle to introduce the brand in specialbranded packs and in larger festive tin packs. By the year 1949, ParleGlucose biscuits were available not just in Mumbai but also across thestate. It was also sold in parts of North India. The early 50s produced over150 tones of biscuits produced in the Mumbai factory. Looking at thesuccess of Parle-G, a lot of other me-too brands were introduced in themarket. And these brands had names that were similar to Parle GlucoseBiscuits so that if not by anything else, the consumer would err in pickingthe brand. This forced Parle to change the name from Parle Glucose Biscuitsto Parle-G. Originally packed in the wax paper pack, today it is available in acontemporary, premium BOPP pack with attractive side fins. The newairtight pack helps to keep the biscuits fresh and tastier for a longer period.Parle-G was the only biscuit brand that was always in short supply. It was heading towards becoming an all-time great brand of biscuit. ParleGstarted being advertised in the 80's. It was advertised mainly through pressads. The communication spoke about the basic benefits of energy andnutrition. In 1989, Parle-G released its Dadaji commercial, which went on tobecome one of the most popular commercials for Parle-G. The commercial was run for a period of 6 years.Parle-G grew bigger by the minute. Be it the packs sold, the areascovered or the number of consumers. It became a part of the daily lives of many Indians. It wasn't a biscuit any more. It had become an
icon.The nextlevel of communication associated the brand with the positive values of lifelike honesty,sharing and caring. In the year 1997,Parle-G sponsored the tele-serial of the Indiansuperhero, Shaktimaan that went on to become a huge success. Thepersonality of the superhero matched the overall superb benefits of thebrand. Parle extended this association with Shaktimaan and gave away a lotof merchandise of Shaktimaan, which was supported by POS and presscommunication. The children just could not get enough of Parle-G and Shaktimaan. In the year 2002, it was decided to bring the brand closer to the child who is a major consumer. A national level promo - `Parle-G Mera SapnaSach Hoga' was run for a period of 6 months. The promo was all aboutfulfilling the dreams of children. There were over 5 lakh responses and of that, over 300 dreams were fulfilled.Dreams that were fulfilled ranged from trips to Disneyland at Paris &Singapore; free ride on a chartered plane; 20 scholarships worth Rs 50,000;a special cricket coaching etc.The year 2002 will go down as a special year in Parle-G's advertisinghistory. A year that saw the birth of G-Man - a new ambassador for Parle-G.Not just a hero but also a superhero that saves the entire world, especiallychildren from all the evil forces. A campaign that is not just new to theaudiences but one that involves a completely new way of execution that isloved by children all over the world – Animation To make the brand much more interesting and exciting with children, it was decided to launch a premium version of Parle-G called Parle-G Magix in the year 2002. Parle-G Magix is available in two exciting tastes -‘Cocoh’and‘Cashew’. The year 2002 also witnessed the launch of Parle-G Milk Shakti,which has the nourishing combination of milk and honey, especially launched for the southern market.
Parle Legacy
MILESTONES - THE DECADES OF PROGRESS
? 1929 ? 1939 The first year of operation. Their only assets were hard work and hope. Ten years of determined effort brought results. Things began to take shape. And they tried even harder.
? 1949 ? 1974
The formative years were over. They had come of age. It was the first evidence of Parle as it is today.
Product strategy Product Levels 1) Core benefit- the core benefit of biscuits is to satisfy hunger of the consumer 2) Basic product- in the second level, the basic product is biscuits. 3) Expected product- the consumers expect the product to have a good taste andalso give nutrition. 4) Augmented product- parle biscuits increase a person’s energy levels. This is notalways expected by the consumers and hence exceeds customer’s expectations.5) Potential product- in the future parle could come up with different products suchas a snack which could be a combo of chocolate and biscuit. Classification of products 1) Based on tangibility- Parle biscuits are tangible, i.e. one can see and touch them. 2) Based on functional life- Parle biscuits are consumables since biscuits form apart of food and have a short life. 3) Based on price and quality- most of Parle biscuits such as Parle-G, Monaco,Krackjack are mass products but a few Parle biscuits such as Parle hide and seekand Milano are premium or prestige products. 4) Based on utility- Parle biscuits are convenience goods. They are staples sincethey are bought by consumers regularly. Also they are partly impulse products
Brand The Parle Biscuit brands, such as, Parle-G, Monaco and Krackjack enjoy astrong imagery and appeal amongst consumers. Be it a big city or a remotevillage of India, the Parle name symbolizes quality, health and great
taste. And yet, this reputation has been built, by constantly innovating and catering to newtastes. This can be seen by the success of new brands, such as, Hide & Seek andHide & Seek Milano. • Brand name strategyParle follows company brand name strategy , since all its products are namedusing the company’s name as a prefix such as Parle-G, Parle- Monaco, Parlehide&seek, Parle digestive Marie, etc. •Brand strategy decision: Old Brand name New Parle follows both line extension and brand extension for its products. For a product like Parle-G it followed line extension with the introduction of Parle-G milk Shakti and Parle-G magix which has 2 flavors- choco and cashew .For Parle Monaco too it followed line extension when a new favor Monaco jeera was introduced. Similarly when it introduces any new product in the biscuit category, it follows line extension.Initially Parle used to produce only confectionaries. Parle followed brandextension with the introduction of products in the biscuits and snacks category.In this way, by concentrating on consumer tastes and preferences andemphasizing Research & Development, the Parle brand grows from strength tostrength.
Various units of The 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 ? Hyderabad (Andhra Pradesh)
Manufacturing process flow chart
Manufacturing of Product
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 Baking powder) Milk solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough conditioners (E 223) and contains added flavours.
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.
Wastage
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.
Loose Biscuits
On the stalking table one to two rows of baked biscuits are kept aside for selling it as loose biscuits. They are normally assumed to be damaged biscuits but they are not damaged or broken but company keep such loose packets of biscuits to sell it to the local people for marginal rate of 33 Rs / kg.
? Stephen Mixer
The FOLLWING ARE THE MACHINERY USED IN MANUFACTURING 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 advantages are compelling: High volume output results from the short kneading time and fast ingredient charging: 1000 kg/h to 6000 kg/h depending on the model. Totally unassisted automatic discharge combines with predividing of the dough into approximately 15 kg. Pieces, is the basis for a fully automatic operation without the need for any full-time operator. Dosing of flour, water, yeast, salt, shortening and other nutrients. In a few seconds, all ingredients are homogeneously mixed. Then, as the dough begins
to develop, the Stephan energy meter control will ensure each dough is finished to the same development The Stephan Mixer is most economical with: No-time dough formula Straight dough Liquid broth (yeast slurry) system Flour fermented liquid sponge system. From batch to batch, the doughs will be consistently uniform: "Process Control" Compact construction, no building preparation necessary, almost service-free day-toThe direct drive design allows the kneading element to be fastened directly onto motor no coupling or power transmission. Easy to clean. Only solid stainless steel construction. Quiet operation, less vibration. Count on a better result. In these competitive times, good kneading is not enough. For a profitable operation, you need a short process time and an exact control on input energy which allows you to mix each dough to the same development curve. A short amortization of the capital investment occurs due to an increase in productivity - more finished product from same amount of flour - and due to a perception of better quality in the areas of longer shelf life, "a delicate crumb", softer crumb structure, higher volume and increased flavor. day operation. shaft. There is
The process control is simple and reliable. The processes of ingredient loading, mixing and dough discharge are
controlled by each program. Depending on the ingredient loading system design, the recipe change needs no change of program. However, if the dosing system can not be adjusted independently, then a different program can be used for each recipe. The ingredient loading system should be designed to allow each scaled ingredient to be weighed during the mixing time of each previous batch. With this pre-scaling or staging of ingredients, all ingredients are ready to be charged at the same time. This system design will save time and thereby increase output. This control system would operate the entire loading, batching, mixing, discharging and dough conveying system. This would include the logic for accurate scaling of ingredients. Here's how the Stephan Mixer works.
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.
Stephen Mixer
The Quality Commitment
Parle Products has one factory at Mumbai that m a n u f a c t u r e s b i s c u i t s & confectioneries while another f a c t o r y a t B a h a d u r g a r h , i n H a r y a n a m a n u f a c t u r e s biscuits. Apart from this, Parle has manufacturing facilities at Neemrana, in Rajasthanand at Bangalore in Karnataka. The factories at Bahadurgarh and Neemrana are the largest such manufacturing facilites in India. Parle Products also has 14 manufacturingunits for biscuits & 5 manufacturing units for confectioneries, on contract.All these factories are located at strategic locations, so as to ensure a constant output& e a s y distribution. Each factory has state -of-the-art machinery with a u t o m a t i c printing & packaging facilities.All Parle products are manufactured under the most hygienic conditions. Great care isexercised in the selection & quality control of raw materials, packaging materials & rigid quality standards are ensured at every stage of the manufacturing process
The major products offered by Parle-G industries are the following: 1.Brand Name: GoodDay and Marrie from Parle Gare stable and are the most established brand in biscuit segment being equated for biscuits for long time. Now the brand has taken a dent though among the present generation with competitors coming up with more powerful advertising campaigns and offering more variety. 2.Styling & Packaging: P a r l e G o f f e r i n g s h a v e t h e i n n o v a t i v e d e s i g n s a n d packaging as compared to what is offered by the competitors. As it's a variety seeking product the styling and packaging helps in getting more customers. 3. Quality: ParleG name is associated with quality. The offerings from ParleG are of best quality when it comes to taste and hygiene. Under it's mission statement "eat healthy think better"
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