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CONTENTS
The story of one of India's favorite brands reads almost like a fairy tale.
Once upon a time, in 1892 to be precise, a biscuit company was
started in a nondescript house in Calcutta (now Kolkata) with an initial
investment of Rs. 295. The company we all know as Britannia today.
The beginnings might have been humble-the dreams were anything
but. By 1910, with the advent of electricity, Britannia mechanized its
operations, and in 1921, it became the first company east of the Suez
Canal to use imported gas ovens. Britannia's business was flourishing.
But, more importantly, Britannia was acquiring a reputation for quality
and value. As a result, during the tragic World War II, the Government
reposed its trust in Britannia by contracting it to supply large quantities
of "service biscuits" to the armed forces.
Today, more than a century after those tentative first steps, Britannia's
fairy tale is not only going strong but blazing new standards, and that
miniscule initial
investment has grown by leaps and bounds to crores of rupees in
wealth for
Britannia's shareholders. The company's offerings are spread across
the spectrum with products ranging from the healthy and economical
Tiger biscuits to the more lifestyle-oriented Milkman Cheese. Having
succeeded in garnering the trust of almost one-third of India's one
billion population and a strong management at the helm means
Britannia will continue to dream big on its path of innovation and
quality. And millions of consumers will savour the results, happily ever
after.
MILESTONES OF BRITANNIA
OFFICES OF BRITANNIA
HISTORY OF BISCUIT.
The word 'Biscuit' is derived from the Latin words 'Bis' (meaning
'twice') and 'Coctus' (meaning cooked or baked). The word 'Biscotti' is
also the generic term for cookies in Italian. Back then, biscuits were
unleavened, hard and thin wafers which, because of their low water
content, were ideal food to store.
The English, Scotch and Dutch immigrants originally brought the first
cookies to the United States and they were called teacakes. They were
often flavored with nothing more than the finest butter, sometimes
with the addition of a few drops of rose water. Cookies in America were
also called by such names as "jumbles", "plunkets" and "cry babies".
The macaroon - a small round cookie with crisp crust and a soft interior
- seems to have originated in an Italian monastery in 1792 during the
French Revolution.
The inspiration for fortune cookies dates back to the 12th and 13th
Centuries, when Chinese soldiers slipped rice paper messages into
moon cakes to help co-ordinate their defense against Mongolian
invaders.
The Origin of 'Eat Healthy Think Better'
Britannia saw the writing on the wall. Its "Swasth Khao Tan Man Jagao"
(Eat Healthy, Think Better) re-position directly addressed this new
trend by promising the new generation a healthy and nutritious
alternative - that was also delightful and tasty.
Thus, the new logo was born, encapsulating the core essence of
Britannia - healthy, nutritious, optimistic - and combining it with a
delightful product range to offer variety and choice to consumers
II. All factories and depots maintain high standard of hygiene which
ensure that our products are healthy and safe or consumption.
PRODUCTS OF BRITANNIA
GOOD DAY
Britannia Good Day was launched in 1986 in two delectable avatars -
Good Day Cashew and Butter. Over the years, new variants were
introduced - Good Day Pista Badam in 1989, Good Day Chocochips in
2000 and Good Day Choconut in 2004.
This rich biscuit enjoys a fan following of consumers across all ages,
loyal to the brand promise of a great taste evident from the visibly
abundant ingredients. Good Day is amongst the fastest growing brands
in Britannia's portfolio and is today the market leader with almost 2/3
share of the market. The brand is synonymous with everyday treats
that infuse happiness into people's daily lives.
The brand perseveres to infuse cheer, hearten the nation and enliven
lives. With its rightful place on the front page of The Times of India,
Good Day gifts the nation a priceless treasure, that of spreading JOY!
TIGER
Tiger, launched in 1997, became the largest brand in Britannia's
portfolio in the very first year of its launch and continues to be so till
today. Tiger has grown from strength to strength and the re-
invigoration in June 2005 and more recently, in Apr 2008 has further
helped bolster its growth in the highly competitive glucose biscuit
category.
Over the years, Tiger has become the mass-market face of Britannia
symbolising fun and energy in both urban and rural India, and
transcending glucose biscuits.
IRON ZOR helps make mind sharper and body stronger. A Rs.4 pack
has as much IRON ZOR as that in 1 kg of Banana.
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana
is accessible to all, being available in convenient packs priced at Rs.2,
Rs.4 and Rs.10.
50-50
With a brand name like 50-50, can the product be anything but fun?
Launched in 1993, 50-50 belongs to the family of crackers and is
considered the "very very tasty tasty" snack.
Britannia 50-50 is the leader in its category with more than one-third of
market share. The versatile and youthful brand constantly aims to
provide a novel and exciting taste experience to the consumer. As a
result, in 2001, the delicious Maska Chaska was launched as a variant
of the original brand and became an instant success.
BOURBON
MARIE GOLD
Britannia's oldest brand enjoys a heritage that spans the last 50 years -
and going strong. In a market swamped with me-too products and
where even the name 'Marie' has become generic, Britannia Marie Gold
has maintained its stronghold. Today, the ever-popular Marie Gold is
synonymous with the 'Tea Time Biscuit'. Its taste, crispiness and
lightness make it a must for every tea break. It is the #1 brand in its
category by a long shot.
MILK BIKIS
Kids may dislike drinking milk, but they love Britannia Milk Bikis! Milk
Bikis has been trusted by mothers as a source of growth energy of milk
and their loyalty to the brand has made it an integral part of their
children's nutrition regimen.
In 1996, Milk Bikis launched a variant called Milk Cream. These round
biscuits come with smiley faces and are full of milk cream that makes
them very popular with children. Milk Cream also promoted the idea of
'eating milk' in a yummy way, which makes mothers happy as well.
To keep pace with the demands of the new generation and to bring
milk nutrition to the masses in a delightful form, Milk Bikis, went one
step further in the last quarter of 2006 in providing not just energy but
‘developmental fuel’ for children. With a unique and attractive
honeycomb design and an enhanced product experience, the new
biscuit is now fortified with SMART NUTRIENTS – 4 vital vitamins, iron
and iodine, proven to aid mental and physical development in growing
kids.
LITTLE HEARTS
Little Hearts was launched in 1993 and targeted the growing youth
segment. A completely unique product, it was the first time biscuits
were retailed in pouch packs like potato wafers. The launch message
introduced a special taste experience that made the unlikeliest
characters - like Dracula and Frankenstein - melt. In 1997, the 'Direct
Dil Se' campaign encouraged youngsters to openly express their
feelings. And in 2003, two variants called Little Hearts Chocolate and
Little Hearts Sesame were rolled out with a campaign "Dil sabka
actually sweet hai". With Little Hearts, Britannia has tasted the sweet
taste of success.
BAKING: This is the area where we pass these moulded wet biscuit
into baking oven .The biscuits are baked on desired temperature
s.Various type of heating are available now days as per the
convenience and cost .Different type ovens are available
PACKING: These biscuit are then stacked and fed into packing
machine for packing. Different packing material are available for
packing of these biscuit in different packs .slug packs , pouch pack or
family packs etc. These packs are then put into secondary packaging
like cartons to be transported to retailers.
Methods of Mixing:
This is a process where all ingredients are put together in right
proportion for
dough formation. These ingredient are then fed into Mixers where
mixing is done
and dough is prepared for molding .Major ingredients are flour , fat
,sugar and
others as per the product One would like to have..
Mixing can be done in One stage ,two stage or three stage s.
One stage or all in One is type of mixing where all ingredients and
water are
added once .Mixing is allowed till satisfactory dough is prepared
.Normally this
type of mixing is used for hard Dough.
Stage two: Salt , chemical and flavours with colors are mixed with
water.
Stage three : Flour with water is then added to the prepared cream
and mixed till
satisfactory dough is prepared .
For cracker variety dough are had additional ingredient yeast and
dough are kept
for 10- 24 hrs .
MIXERS
• Spiral
• Planetary
LAMINATOR
• horizontal laminator
• vertical laminator
GAUGE ROLLS
• pre sheeter
• two stand rolls
• three stand rolls
• four stand rolls
•
CUTTING MACHINES
moulder
• engraved type
• die type
•
cutter
• engraved type
• cup type
Oven
CONVEYOR
PACKING MACHINES
SPRAY MACHINES
• oil spray unit
• salt and sugar depositors
PUMPS
• Centrifugal pumps
• reciprocating pumps
• twin lobe pumps
• screw pumps
• pneumatic pumps
REFRIGERATION EQUIPMENT
• chiller
• cold storages
• direct expansion type chillers
HEATING EQUIPMENTS
• boiler
• hot water generator
• Forklift
• pallet truck
• power conveyor
• floor mobile crane
• trolleys
Sell by date
Expiration date
Lot number
Recyclable
Environment friendly
INSIDE INFORMATION
Food labels and packaging are excellent sources of information about food and
guides for food safety. If you don't take time to read them, you are not taking full
advantage of this food information resource. Look for the following on food labels and
packaging:
How nutritious the food is. This may include the number of calories per serving,
amount of fat, and percentage of vitamins.
How the food should be stored or prepared.
The food's shelf-life dates. These may include the date product was manufactured,
processed, or packaged.
The "sell by" date. This is the last day the product can be sold. It allows time for the
product to be stored and used at home.
The "best if used by" date. This is the freshness date; product may be safe after this
date but will probably not be at peak quality.
The "do not use after" date. This is the expiration date; the last date the product
should be used.
The lot number of the package. Manufacturers place batch identification numbers on
food packages.
If there is a problem with a batch of food, news reports will advise people to return
products with a certain number.
Anti-tampering devices. These will reveal whether the container's original closing has
been broken.
The name and address of the manufacturer or packer of the food.
PROCESS DESCRIPTION
1. Britannia has laid down their standard specification as per BIS for
all raw materials, chemicals and packaging materials. After arrival
of material, samples are taken and analyzed in Quality Control
Laboratory. After testing if the material is in the range then it is
accepted and unloaded otherwise rejected and sent back to the
party.
Production Section:
Packaging Section:
1. After stacking, biscuit are automatically fed to the packing
machine without touching by hands. Biscuits are packed in
already printed thick wax paper. Then desired number of
packets are further packed in poly bags and finally in
cartoons.
These are baked products made from dough using flour, fats, liquid (water, milk,
eggs), salt, sugar, leavening agents and flavouring agents. Based on the dough
characteristics 7 dough making procedures, biscuit are of the following two
types:-
Flour/Maida:
Sugar:
The Sugar plays very important role during manufacturing of biscuits.
Important characteristics are given as under:-
a) when creamed with fats, it helps in incorporation of minute cells
in the mixture. Act as antioxitand for fat and increases keeping
quality.
b) Sugar caramelizes during the process of baking and thus imparts
an appetizing crust colour and improves the general appearance
of finished products.
c) Sugar im[proves flavour of the product.
d) Particle size of sugar has definite effect on response of dough to
oven heat and on the size and texture of bicuit.Hence it acts as
textirizer & also controls of spread of biscuit.
e) Reduces Gluten strength.
f) It, being hygroscopic in nature, assists in moisture retention in
the product.
g) It increases the nutritional value of the biscuit.
Salt:
It is most effective concentration is around 0.75units based on the flour
weight basis. Beyond this concentration it slows down the rate of
fermentation and also onhibits the action of proteolytic enzyme on
gluten. Important characteristics are as under:
a) It causes strenghthening effect.
b) It gives taste to the product.
c) It plays role to maintain colour.
d) Helps in gluten development.
Ammonium-Bi-Carbonate(ABC):-
ABC is extremely volatile salt which when heated liberates carbon-di-
oxide, ammonia gas and water. ABC is extensively used forv products
which are baked to low moisture contents. Its leavening effect is due to
NH3, CO2 and steam due to action of heat.
a) it is leavening agent. It is responsible for puffing.
b) It is resoponsible for Maillared reaction as it maintains acidity.
Sodium-Bi-Carbonate(SBC):-
It is an important leavening chemical used widely. It produces carbon
di oxide in presence of acid component. The acid component reacts
with soda, when it gets moist it produces carbon di oxide and steam
due to action of heat.
Water:
Water is unique ingredient in biscuit dough. Almost all the water added
to biscuit dough is subsequently removed in oven, but the quantity of
water used have effect on dough consistency. Important
characteristics are given as under:-
a) It mainly acts as moistening agents for dry agents.
b) It is basic reaction medium for different ingredients
in biscuit dough.
c) Helps in homogeneous mixing.
d) Helps ih gluten formation.
e) Maintains texture of biscuits.
f) Affects the stack height.
Sodium-Meta-Bi Sulphate(SMBS):-
It is a mellowing agent which breaks the gluten network and softens
the dough. It also releases Suphur di Oxide which acts as preservative.
Preparation procedure:
Mixing:-
Mixing is done in three stages for a batch preparation.
• CREAMING
• DRY MIXING
• WET MIXING
A) CREAMING:
Fat + Emulsifier(Soya Lecithin) + Flavour Mix+ SMP.
These are churned strongly sothat the floavour may get adhered
to fine droplets of fat. Mixing time is one minute.
B) DRY MIXING:
When creaming is over, the Maida and Sugar powder are also
poured to creamed fat and mixer is operated for 2 minutes.
C) WET MIXING:
Water + Sugar Syrup + Chemicals(ABC+Salt+SBC+SMBS) mixed
in high speed mioxer for 1 minute. Batch is now ready for further
processing.
FEED ROLL:
It is ametal roll. A metal knife is fitted below.
The knife helps to cut excessive amount of batch and allow desired
amount of weight.
DIE ROLL:
It is present between feed roll and rubber roll. It consists
of 360 cups which gives the biscuit a specific shape and impression of
the brand.
RUBBER ROLL:
It is present below the die roll. It helps to pick up
the moulded biscuit through the cotton belt or panner web.
Extraction belt:
It carries the moulded dough from die.Dough on the extraction belt is
prevented from sticking by using steam from lower side of extraction
belt.
CROSS CONVEYOUR:
The blade remove scrap attached to extraction belt and make it is fall
on the cross conveyour, scrap is collected and again put in dough
conveyour.
Puffing:
It occurs in ovens during banking. It is result decomposition of
Ammonium Bi Carbonate into Ammonia, Carbon, Water.
Colouring:
It occurs during baking. Sugar is responsible for colour development in
biscuit at high biscuit. At high temperature sugar caramelizes and
imparts crust colour.
Cooling:
After the biscuit are allowed to travel on the cooling conveyor for
something to lower down the biscuit temperature before packing. For
the purpose of cooling there are two cooling conveyors.
Cooling conveyor-I
an industrial metal detector is fixed just before the
end of conveyor.
cooling onveyor-2
It carries biscuit from cooling conveyor to stacker.
Stacking:
A Stacker takes up the biscuits from cooling conveyor and aligns them
in rows. The aligned biscuits are fed into auto feeding machines to
packing machine. A brush roll is fitted above the stacker to control the
movements of biscuits.
Packaging:
packaging is done by packing machines. The machine automatically
wraps the wrapperas around the biscuits. Sealing of biscuits is done
with the help of roller heaters. Some heaters are used for side and
some from cross sealing (lengthwise)
↓
Slurry Preparation
(Maida +Sugar yeast +Chemicals + Water)
↓
Batch Weighing
(Addition of more ingredients- Maida,
sugar, fat, scrap, sugar syrup, salt, SBC,
SMBS, ABC, Flavour etc.)
↓
Mixing In Dough Mixer(10-12
minutes)
↓
Laminating
↓
Sheeting and Maida Spreading
↓
Brushing
Contd.
↓
Moulding
↓
Baking
↓
Spray Field Oven
↓
Oil Spraying
↓
Cooling
↓
Packaging
QUALITY ANALYSIS:
Maida:
Special care is taken to mtest maida as it is an important ingredient
used in biscuit making and its property affects the biscuit quality. For
example, if excess bran is present in maida , it will impart dark colour
to dough which will further affect the biscuit colour and texture. Soft
and medium hard maida is used for biscuit processing, maida is tested
for various properties in lab which are:
a) DETERMINATION OF GLUTEIN CONTENT:
The Strength of flour depends upon both the amount
and physical qualities of glutein. Crude glutein obtained
in this way contains, albumin, glutein, globulin,gladin
and protease.
b) SEDIMENTATION VALUE:
The volume of se