Dhiman Engineers (Regd.

)
Dakhni Gate, Nakodar - 144 040, Distt. Jalandhar, Punjab, INDIA
Phone +91-1821-220 300 Fax +91-1821- E-Mail : dhimanindia@hotmail.com
500 300 / 220 600 222300 dhimanindia@yahoo.com
500 001 / 226 666 dhimanIndia@gmail.com
500 012 / 223 900 URL : www.dhimanindia.com

WORKING PROCEDURE FOR MANUFACTURING

TOFFEE MAKING
Cooking of Toffee Batch
There are two ways to cook the Toffee batch.

1. Open Fire Cooking Method

2. Cooking of batch in Steam Jacketed Toffee Cooker

Open Fire Cooking Process:

In this procedure Diesel Bhatti and Karahi or any other mean is used to cook the
Toffee Batch. The batch is manually stirred while cooking. This process is caused to
pollution also.

Cooking process in Toffee Cooker

In this process Stainless Steel Steam Jacketed Toffee cooker with Motorised
Stirring system is used to cook the toffee batch. The Batch is cooked with steam hence
there is no pollution in the cooking area.
Steam is generated in Boiler far away from cooking area. And the steam is fed
directly to Toffee cooker through a pipeline. First of all Water is put in the cooker and
required quantity of sugar added. Steam is opened and stirring systems is also operated.
When the sugar dissolved liquid glucose and other ingredients are added in the cooker.
After cooking the batch at a required heating level upto a specified time, the batch is tilted
manually on cooling plate. Cooling plate with water circulation inside of plate is used to
cool down the batch and mix flavours, milk powder etc. manually.

Cutting & Wrapping Process

After cooling and mixing flavours etc. in the batch, the batch is put into Batch
Former. Batch former forms a conical type of thick rope of the batch and further the rope
is fed to Five-Stage Rope Sizer. Five-stage rope sizer reduces the dia of rope in required
size and weight. Further the rope is fed to cut & Wrap machine.
There two types of wrapping of Toffees
a. Double End Twisting Style
b. Fold Wrap Style

a. Toffee cut & Wrap machine double twist style is used to cut & wrap the toffees
in double end twisting style. This machine automatically cuts the rope and paper in
required size, covers the toffee with paper and twists both ends of toffee and
delivers the wrapped toffee to tray. The wrapping speed of this machine is 300 pcs.
Per minute.

b. Toffee cut &Wrap machine Fold Wrap style is used to cut and wrap the toffee in
Fold Wrap style. This machine also cuts the rope and paper in specified length and
automatically folds paper around toffee. The wrapped toffees are delivered to tray.
The wrapping speed of this machine is 600 pcs. Per minute.

FUEL / POWER / WATER / CONSUMPTION

TOFFEE PLANT 500 KGS. /SHIFT

POWER

S.NO. NAME OF MACHINES LOAD NOS. TOTAL LOAD

1. STEAM BOILER 2 Hp. ONE 2 Hp.

2. TOFFEE COOKER 1.5 Hp. ONE 1.5 Hp.

3. BATCH ROLLER 0.5 Hp. ONE 1. Hp.

ELECTRIC HEATER 0.5 kW. ONE 0.5 kW.

4. ROPE SIZER 2 Hp. ONE 2 Hp.

5. TOFFEE CUT & WRAP 1.5 Hp. ONE 1 Hp.

WATER

1. About 10 litres water required per minute for cooling plate. (this water can be re-
circulated after cooling)

2. About 300 kegs water per hour for the boiler even this can be Collected in the form
of steam condensates and circulated again.

Fuel

1. An oil fired boiler consumer approx. 8 - 10 litres of LDO (light diesel oil) per
hour.
(this boiler can operate up to two cookers)
WORKERS / RAW MATERIALS REQUIRED
WORKERS REQUIRED

S.NO. REQUIRED FOR NO.

1. BOILER AND COOLING PLATE 1. (Semi Skilled)

2. TOFFEE COOKER 1. (Skilled)

3. WEIGHING & DOSING 1. (Unskilled)

4. TOFFEE CUT & WRAP MACHINE 1. (Skilled)

6. HANDLING 1. (Unskilled)

7. PACKING & STORAGE 5. (Unskilled)

Composition of Raw Material per batch of 50 kgs. (Sample)

1. Sugar 30.000 Kgs.

2. Glucose 21.000 Kgs.
3. Water 6.000 Kgs.
4. Condensed Mil 1.000 Kgs.
5. Skimmed Milk Powder 1.000 Kgs.
6. Vegetable Fat 1.500 Kgs.
7. Colour 0.002 Kgs. (can be varied as per requirement)
8. Flavour 0.150 Kgs. (can be varied as per requirement)
9. Emulsifying Agent 0.300 Kgs.

60.952 Kgs.

(After evaporation the net weight of batch will be 55 kgs. Appx.)