Another advantage of this fuel is that its smokeless hence has less effect on bakery worker health .
Following are important features to check before finalizing carton for your product
Regular slotted cartons
This is the most common carton design, and efficient for many applications. All flaps have the same length and the two outer flaps (normally the lengthwise flaps) are one-half the container's width, so that they meet at the center of the box when folded. There is very little manufacturing waste, usually making this type of box the most economical.
Half slotted cartons
Same as Regular Slotted Carton without one set of flaps. Normally used as a cover, an open storage container, a deep tray, or as a bottom part of a 2-piece box where a telescope top would serve as a box cover
The 2-piece box made from two scored and slotted trays.
One piece of board cut so that it provides a flat bottom, with flaps forming the sides and the ends, and extensions of side flaps meeting to form the top. Most common uses include books, paper reams, audio and video, artwork, mirrors, and many more.
Five panel folder
A single cut and scored piece features a fifth panel used as a closing flap, completely covering a side panel. The closed box has several layers of combined board on each end, providing stacking strength and protection for long articles of small diameter which might me damaged, or damage the box if pushed through the ends.
Pads are plain shapes of corrugated fiberboard. They can be used to fill the space between the inner flaps of an RSC, to completely cover the bottom or top of a box, pr to separate layers of product (horizontally or vertically).
Dimension of corrugated box are given L X W X H . These are arrived upon by doing mock exercise with the products .Products can be arranged horizontally or vertically as per the maximum number of packets that can be arranged .So check your product dimensions and its arrangement in CBBS .
Kraft Liner - linerboard manufactured from pulp produced by the Kraft cooking process. This is the most economical type of color because no further processing is applied.
White Top (Klay) Liner - a two-ply sheet composed of one bleached and one unbleached layer. Terrace Paper Company uses a high quality grade of klay, thus very little kraft surface of the unbleached kraft layer shows through. White-top corrugated board can be ordered one-sided (only one linerboard is White Top, the other is Kraft) or two-sided (both linerboards are White Top).
Bleach Liner - liner that is composed entirely of bleached virgin fibers, making it white throughout. This corrugated board can also be ordered one-sided or two-sided (with either one linerboard or both linerboards bleached).
Burst Test is a traditional form of measuring box strength (also known as Mullen Test). Burst Test is the force required to rupture board hydraulic pressure. This force is measured in pounds per square inch. Thus, a box’s burst strength of 200 test indicates that this box can withstand 200 lbs of hydraulic pressure per square inch. Burst strength relates to individual box’s ability to withstand internal or external forces and to contain contents during rough handling. Out of the two types of test board, Burst Test board is considered a stronger and better quality kind.
The Edge Crush Test (ECT) is another form of measuring box strength and it measures top-to-bottom compression strength of the finished box. Thus, it is usually measured by stacking weight on top of a carton until it crushes. This force is also measured in pounds per square inch. Thus, a box with a 44 ECT indicates that its board can withstand a force if 44 pounds per square inch before crushing. The higher the ECT number is, the stronger is the compression that box can withstand.
Compression strength may be important depending on the types of materials and filling capacity of the box. When a box is packed with heavy material and NOT filled all the way to the top, it is more likely to crush when other boxes are stacked.
Single Face - one medium is glued to one flat sheet of linerboard.
Single Wall - the medium is between two sheets of linerboard. Also known as Double Face.
Double Wall - three sheets of linerboard with two mediums in between.
C-flute: the largest in size and most commonly used material. Offers superior stacking strength and is commonly used for shipping cartons.
B-flute: thinner than C-flute, provides good puncture resistance, commonly used for die-cut boxes and shipping cartons.
E-flute: lightweight, great printing surface, commonly used for die-cut boxes and retail packaging.
F-flute: very lightweight, easily folded, excellent printing surface. commonly used for retail packaging and small die-cut boxes.
Britannia dominated the premium segment of biscuits where as parle dominated the mass ,low premium biscuits ,things were pretty predictable but for the
entry of new players have changed that status .Now that ITC and Priya gold are trying to break into their market and have established them selves as important players in biscuit market . These two major biscuit producers has are now forced to innovate products by the consumers to create brands which could be differentiated .
Both are trusted brand are ranked in top brands for biscuit ,both have a long history of brands . The Major difference though is that where Britannia is revenues from bakery products is around 90 % ,share of biscuit sales is around –80% for parle
Recently two categories has seen major ad war are bourbon and salty snacks . Parle has come up with new bourbon under its hide and seek umbrella brand .Pitching against Britannia s popular bourbon which has 70% market share of the bourbon biscuits . Parle upped its TV ads by roping in Hritik roshan . Similarly Parle has re jigged its Krack Jack biscuits to Britannia's 50- 50 eating up its market share . Krack Jacks with new packaging and TV ads of Krack and Jack promoting the brands . It would be interesting to see what impacts these would have on the sales of these two biscuits .
PARLE VS BRITANNIA
|Nature of business||Public ltd||Family run business|
|No of manufacturing units||5 own ,40CMU||8 own units ,60 CMU|
|Market share ( value)||32.80%||32.94%|
|Ads Major methods||Cricket events and players||Celebrities endorse ment|
|New areas of promotion||Environment||Health and wellness|
|Marie||Marie Gold||Parle Marie||Marie Gold|
|Salty snacks||50-50||Krack Jack||Krack Jack|
|Choco chips||Good day||Hide n seek||Good day|
|Milk||Milk bikis||Milk sakhti||Milk bikis|
|Bourbon||Bourbon||Hide n Seek||Bourbon|
|Multi grain||Nutri choice||-----||Nutri choice|
|Cream||Cream Treat||Kreams||Cream treats|
|Cookie||Good day||20-20||Good day|
"Parle-G, which contributed to more than 70% of Parle’s revenues a couple of years ago, now accounts for 60-65%. According to a report released last month by Motilal Oswal, contribution of the glucose segment to ITC Foods’ revenue has come down from 56% in 2007-08 to 48% in 2008-09. Britannia’s largest brand Tiger yields just over 20% of the company’s revenue."
Ref : ET .
The ever increasing Indian middle class are now experimenting different categories of cookies /biscuits at premium range .Tapping this market Britannia , ITC , Parle all have come up with their own product . such as Britannia s Nutrichoice , Parles Hide and seek bourbon biscuit . The Genius of Parle G is waning .
Earlier food manufacturers were subjected to plethora of acts and laws e.g PFA Act , Weight and measurement Act ,Act for milk , Act for Edible Oils , Act for meat processing units etc .These laws would be merged into single entity and would be implemented in phased effective from January next year .
The licence for the larger industries would be issued from the government of India while the state governments will issue the licence for smaller industries. 'Since licences for smaller industries were issued by bodies like panchayats and municipalities, we are now working on getting all these integrated into one licence,' Mr Suvrathan said. Mr Suvrathan is the CEO of the FSSAI .
FSSAI is working on comprehensive Act which is being formulated with analysing present standrads in other countries and Codex Alimentarius.Each sectors has been studied and standards matched with best practises across the globe .
Labelling and Advertising laws are also under review .
Bakery business requires knowledge of finance , marketing , production , maintenance ,Ingredients ,packaging , food safety and hygiene . After a little surveys for issues like market competition , buying habits , neighborhood ( small bakeries) would help in deciding the nature of bakery business .Following options are there for any business men to enter bakery business .
- Home made bakery products.
- Artisan bakery chain
- Automated bakery plants
- Small Bakeries
- Third party manufacturing/private labels(outsourcing)
- Export/ Import
- Retail chain
- Online shops
- Pet animal food ( DOG BISCUIT )
- Food Additive manufacturing
- Packaging material manufacturing
- Bakery equipment manufacturing
Ebook on bakery manufacturing process
With demands on rise for bakery products in this region ,opportunities are there for business men and entreperneur to set up or do business in these region . ASEAN countries have strated producing and exporting their baked products across the globe .
Here are few major bakery manufacturers of ASEAN countries
- Kraft Foods S.A
- P.T.Khong Guan Biscuit Factory
- P.T.Mayora Indah
- P.T. Nissin Biscuits Indonesia
- P.T. Pacific Millenia Pangan Makmur
- Crown Confectionery Co ltd
- Lotte Confectionery Co ltd
- Apollo Food Industries
- Gandour Sdn .Bhd
- HupSeng Perusahaan Makkanan Sdn Bhd
- Kinji Baking and Packaging machinery Co
- Oriental Food Industries Sdn .Bhd
- Silver Bird Group Bhd
- Apollo Food Holdings Bhd
- Gardenia Bakeries Sdn Bhd
- Croley Foods Manufacturing Co .
- First Choice Food Co.
- Monde Nissin Co.
- Republic Biscuit Co.
- Universal Robina Co.
- Gardenia Bakeries
- European Food Public Co. Ltd
- URC - Thailand
- Bien Hoa Confectionery Co.
- Tan Tan Processing Trading Corporation
- URC Vietnam .
- Vinabico Kotobuki Co ltd .
- Eco friendly foods
- Prebiotic and Probiotic foods
- Low fat or Low trans fat products
- Low salt products
- Alternative Sweeteners
- Green packaging
- Labelling and Ingredients
- Natural products or Organic Food
- Gluten free products
- Whole Grain products
- Food safety related labels and symbols
- Higher Price of Food products
Established in year 1930 by John Gregg's at Tenyside . It went on to have seven central divisions and 504 shops by 1994 . It has acquired Bakers Oven and Birketts
Gregg's bakery shop are popular destination for customers who prefer fresh baked products . Gregg's now owns upto 1400 bakery shops through out UK . It operates on regional central bakery supplying bakery products to local retail shops all of then owned by Gregg's. Its 10 such divisions in UK.
Improved shop designs were introduced , with the new Gregg's format offering improved access to takeaway food and speedier service, and Bakers Oven featuring an enhanced seated catering concept. It become most sought out bakeries in the country.
Main products of Gregg's are Sandwiches ,Savouries , Bread , Cakes and Regional Specialities bakery products .
Default on rent has been cited as the reason for this action .As per the notice Britannia has not paid its due since 1989 . Against outstanding of Rs 12.0 crore BIL has only paid Rs 3.4 crore this dues includes the penalty on non payment .
Britannia has taken two plot of 45000sqm and another 35000sqm on lease on renewable basis for period of 10 years from CPT . Dispute has arisen as CPT wanted to revise the rent from period of 1967 . The Britannia contested the raise went to High court where the court maintained the raise .
Britannia ,Kolkatta has 200 management staff and 300 workers on the pay roll.
Read complete story source The Telegraph
Food technologist argument is that the food can be contaminated and can have bacterias like Salmonella .Where as Egg liquid manufacturers counters this by the fact that the cost of sterilising the egg liquid it too expensive and bakeries prefer to use non sterilised/pasteurised egg liquid as the process is such that these germs are eliminated during baking .
Eggs are used commercially in bakeries as Eggs in shell , Eggs in refrigerated liquid form , Egg dried powder.Few countries have stipulated that the all egg products to be pasteurised prior to use at 140degF for at least for 3.5 minutes .Other Important standards followed is the bacterial count for egg liquid which is limited to 10000 viable bacteria per gram and for egg white frozen it is 50000 viable bacteria per gram .In addition to bacteria limit for yeast ,molds and coliforms to be less than 10 per gram .
Countries like USA has banned non sterilised egg for food processing industry , where as Japan has sets standards by bacterial count .
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Hindustan times awards- HT City Crystal- for best food and beverages providers declared Wengers pastry shop as the best bakery cafe in bakery section .
Established in year 1926 and Located in the hub of Central Delhi, Wengers, a reputed pastry shop offers you a complete line of individual signature cakes, novelty desserts and assorted minipastries .One of the oldest bakery chain stores in Delhi and pioneers of Swiss confectionery in town.
Wengers do have Online stores from where you can order cakes , pastries
Wenger & Co.
A-16, Connaught Place
New Delhi - 110001
Tel - 2332-4594 / 4403 / 4373
Fax - 23352142
Here are list of few major bakery plants in China
Foshan Confectionery factory – Canton
Gandour Food Co – Suzhou
Kraft Food Asia – Beijing , Suzhou
The Garden Company Ltd- Kowloon
Ting Hsin International Group- Tianjin
URC Shanghai Peggy Foods Co Ltd- Shanghai
Arnotts Biscuits Ltd.
Beijing Delliyana Food Co
Dongguan Gang Lian Food Co. Ltd
Dongguan Golden Apple Food Co. Ltd
Dongguan Golden Fuji Food Co. Ltd
Dongguan Hsu Fu Chi Foods
Dongguan Huamei Foods Co. Ltd
Dongguan Jia You Food Co. Ltd.
Dongguan Kam Tai Co. Ltd
Dongguan Lap Chau Foodstuff Co. Ltd
Dongguan Yi Dong Foodstuff Co. Ltd
Four Seas Group
Fujian Dali Group
Gang Rong Foodstuff Development Co. Ltd.
Garden Li Hua
Garren Biscuit Co
Ginbis Four Seas (Shantou) Co. Ltd
Gong Yang Foodstuff Co. Ltd
Guangdong Jiashili Group
Guangzhou Jessica Food Products Co. Ltd
Guangzhou Oubao Food Co
Hai Tai Confectionery
Hangzhou Kaida Biscuit Co. Ltd.
Hebei Hualong Biscuit Corp
He Tian (Dotin)
Hua Jia Food Co. Ltd.
Jiangmen Danone Biscuits Co.
Khong Guan (S) Ltd.
Kotobuki Seika Co. Ltd.
Kum Ho Foods (Qingdao) Co. Ltd
Lotte Stone Foods Co. Ltd
Meiji Seika Kaisha
Orion Food Co. Ltd
Qingdao Food Co.
Qingdao Guliguo Food Co
Quanzhou Harvest Foodstuffs Co. Ltd
Shandong Navigable Food Co. Ltd
Shanghai Danone Biscuits Foods Co. 148
Shanghai Ezaki Glico Foods Co. Ltd. 151
Shanghai GT Nissin Food Co. Ltd. 155
Shanghai President International Foods 159
Shantou Maohuat Foodstuff Co. Ltd. 163
Shenzhen Rungu Food Co. Ltd. 165
Taishan Entally Enterprises 168
Tianjin President International Food Co. Ltd
Tianjin Ting Yuan International Food Co. Ltd.
Tong Yang Confectionery Co. Ltd.
Uni-President Enterprises Corp
Universal Robina Corp
Want Want Holdings Ltd.
Xian Food Factory
Yantai Alliance Food Co. Ltd.
Yat Hing (China) Co
Yi Shui Qing Yang
Zhongshan Mei Hua Co.
Zhongshan Weiss Biscuit Factory Ltd
Zhuhai Kaidoo & KiuXiu Food Co. Ltd
Few basic design consideration of biscuit packaging .
- Select your target consumers .
- Select your graphics /pics/theme before finalising the print .
- Select your color patterns with concepts like matching colors / contrast / black white / plain / colorful . Try to match with your target consumers
- Finalise how to pack the product whether its flow wrap/pile type or on the edge packing
- Select the type of wrapper you want whether it would be metallised ,pearlised or plain BOPP.
- Select your slogan or the punch lines .
- Check for the labels as per the laws .
- Now check the dimensions of wrapper such as length and width as per product pack.
- Check the cut off length of wrapper as per the pack size . This is important as far as cost is concerned you have to careful not give to large a cut off length or very less margin for packing .Special eye marks are put for sensors .
- Winding directions - wrapper s have to manufactured as per the machine orientation as wells text and picture layout . They can be put into different orientation like anti clockwise or clockwise .Text parallel to the length or across the width .placement of eye mark with respect to printer arrangement .
- Ask wrapper/laminate manufacture to produce two or three samples before approving the final print .
- See the demo through manual packing of the product to see how it looks .
In line with its mission to fill all kinds of fun-eating snacks in every home, Munchy’s products can now be found in nearly 60 countries. Its main products include Mini Crackers, Lite Cream Crackers, Lexus Biscuits, Muzic Wafers, Munchini Wafer Sticks, Sugar Crackers, Muzic Nuss Wafers, Choco-O Mochachip Cookies and Captain Munch Cookies (Milk / Chocolate). Munchy’s incorporates two entities – its manufacturing arm Munchy Food Industries Sdn Bhd (MFI), and MunchWorld Marketing Sdn Bhd (MW). MW is a leading provider of fully-integrated marketing and distribution services representing Super Coffeemix Manufacturing Ltd., Unistraw International Limited’s Sipahh Milk Flavouring Straws, and all things Munchy’s.
Major Competitors –
- Tatawa Industries (m) sdn bhd - Tatawa brand
- SGK food Industry sdn bhd
- Ever Delecious Food Industries
- Hwa tai Industries Berhad
- ShoonFatt biscuit
- Perfect food manufacturing sdn bhd
- Morning Star food Industries sdn bhd
- Tech Seong Food industries sdn bhd
Munchy Food Industries Sdn Bhd
Address: Lot 9366, Batu 7, Simpang 3,Tongkang Pecah, 83010 Batu Pahat, Johor, Malaysia
Email : mailto:firstname.lastname@example.org
- It helps unitizing i.e. keeping products in a compact form .
- Keeps box and product clean
- Consumers can views products
- Convince to consumers in handling
- Helping in palletization
- Extra protection
Fine lady bakeries ltd one of the UK Leading bakery house declared its intention to set up a modern bakery plant at east of Manchester U.K with investment worth 20.0mnGBP
This location provides company a better logistic hub for the movements of finished goods and raw material .Fine lady bakeries are part of Haygate group.Its production capacity is around two million loaves per week . It claims to have the most modern bakeries production facility at Banbury, Oxford shire. Haygate group are UK largest flour miller and has forward integration with its own Fine lady bakeries.
Established in year 1950 in Banbury it has 350 employees provides employment to local people in around that are
It other products range are
- Premium and Standard Breads
- Batch Breads
- Organic Breads
- Sandwich Loaves
- Fruit Loaves
- Sub Rolls
- Torpedo Rolls
- Oval Rolls
- Round Rolls, Cobs and Burger Buns
- Fruited Teacakes and Bun
South am Road
Oxon. OX16 7RR
Tel: 01295 227600
Fax: 01295 271430
After success of Kurkure Frito lay is now experimenting with new category of product which is called cracker to taken on competition from namkeens and salty crackers from major bakery manufacturers . Its had mega launch recently and products is visible on every major shops . Aliva name has been carefully crafted so as to prepare this kind of product in other countries . Frito lay has repeated the product formulation of Kurkure i.e. local flavors for Indian market such as Special Pindi Masala, Original Salted, Mint with Herbs and Tomato, and Roasted Spices. The value proposition is a combination of taste and nutrition. .Frito Lay has developed Aliva for Indian palate though they had wide variety of popular international brands such as SunChips, Doritos, Fritos which could have been launched or replicated .
Aliva has been priced fairly on the premium side a Rs 12/- per pack . Competition would come from Parle Monaco smart chips , Britannia's 50-50 , digestives , multigrain biscuit and ITC -Bingo .
One of the most important event for bakery industry captains is Fi 2009 ( Food Ingredient Europe 2009).Global platform for people in Food industry where one get the “’Next thing “’ and trends of ingredients in food industry .
Fi Europe is held once every two years in a major European city and brings together the world’s leading food and beverage suppliers, R&D, production and marketing specialists and showcases the most diverse range of new and innovative ingredients and services.
Last Fi was held in London in year 2007 ,Around 17,700 converged at the exhibition . This year around 1100 exhibitors from 90 countries would display their products . You can find all kinds of ingredients required in bakery , confectionery ,dairy and beverages . 120 new companies would show case their products .
There would be related conferences , workshop and seminars on subjects like natural ingredients ,quality and safety,probiotics , functional foods ,Omega 3 and many more.
Health aspects and efficiency in bakery manufacturing - solutions to reduce acrylamide in baked products etc . Speakers from Nestle , Mars , Cargill , Danone , Max Planck Institute would address the conference .
Event is organized by
UBM International Media
P.O. Box 200
3600 AE Maarssen
Few are most popular brands of printer and coder used in bakery packaging
- Imaje ( Now Markem )
- Alpha Dot
- Bell- Mark
What we see as labels on bakery product packaging are impressions generated
through printers or coders installed on the packing machine or stand alone machines which prints messages such as
Date /manufacturing batch code /Best before /expiry date/manufacturer address etc .
These printers and coders are integral part of packaging of bakery products and codes can be generated through electronic screen or mechanical brass characters. Various feature are unique to individual types of printers and coders such as number of line for message , Font size , colors ,
Types of printers and coders
- Manual stamps are used in small bakeries where you have rubber characters arranged as per the message and is rubbed with ink pad and then stamped on the area of message .
- Dry ink rolls contact type printers - Coders are mounted on packing machines and dry ink rolls comes into contact of brass characters and printing is done when wrappers come into contact of these characters .Ink rolls are heated so as to get ink in fluid conditions from ink rolls .Various colored ink rolls are available such as red , white , black , blue for colored impression . Major disadvantage is that if we want to change the codes or letter then earlier codes have to be removed from holders . Radial type and Axial type characters are used as per design of type holders ..Life of ink rolls is counted as no of impressions . Number of messages are limited in such kind of coders .This could only print wrappers used for packets and cannot be used for carton boxes
- Ink jet printers – Ink jet printer is another form of printing where ink is injected through nozzle in controlled manner on the wrapper or laminates to generate s message . These could be packing machine mounted or can be stand alone portable kind of inkjet printing machine .Advantages of such printers that we can change the fonts ,colors , language as these are monitored through software . Disadvantage is that it is costlier than contact type coders as it has consumables ink cartridges or ink bottles ,some what clumsy in operations , solvents has to be applied to clean the nozzles .
- Thermal transfer printer - Thermal ribbons are used to print message on the wrapper or laminates for the message . Thin ribbon is passed in between ribbon and the labels ,coating of the ribbon sticks onto the label .These printers give high quality prints with quick change over time for different messages , clean operations .Ribbons wastage are very low . Used for precise and quality printing .
- Laser printer – These are used for high volume and high printing requirement laser beams are generated to produce an image on a drum , the light of laser beam alters the electric charge on the drum this drum then dips into reservoir of toner the charged part s of the drum then picks up the toner this toner is then transferred to the wrapper through heat and pressure .
Here are few market share data for biscuit industry from report s available at IBMA ( Indian Biscuit Manufacturers Association) Fig 2007-2008
- Market Share - Sector wise
|ORGANISED SECTOR||UN ORGANISED SECTOR|
- Market share penetration- Population wise
- Market share - Region wise
- Market share- Brands wise (volume )
- Market Share – product wise
|Marie and Glucose||50%|
|sweet, crackers , cream ,milk||50%|
- Annual growth rate
- Total Production ( In lakh metric ton)
SFAL manufactures popular biscuit brand Priya Gold, besides fruit juices, chocolates, toffees and wafers. It has manufacturing units at Noida, Surat and Lucknow.
"Initially, our products will be available at IOC&aposs outlets in Punjab, Himachal Pradesh, Jammu and Kashmir and Chandigarh, and can be gradually expanded in future by mutual consent,"the official added.
The company has been embarking on different distribution expansion drive in order to increase its sales.
Earlier, it had also won a contract from the Indian Railway Catering and Tourism Corporation to set up food kiosks for sale of its entire range of products at railway stations across various cities in India.
The" Diji" model vending machine would act as mini store for Kraft foods storing crackers , cookies , biscuits and snacks .This snack vending machine is designed specifically for Kraft foods by Samsung Electronics . It would have a 46 "electronic touch screen display for all information and one can see the nutritional values and calories on it .
The computerized devices are linked so that vendors can see when and where goods were bought. That way, they can learn more about customers' habits—do people buy fewer Cakesters after looking up their calorie count?—and test ad messages to find out which trigger more purchases, just as they can on the Internet.
Each Au bon pain cafe has a authentic recipes for savory sandwiches, soups, salads and entrees. Au bon pain has now around 250 cafes across the globe which includes countries like USA , Taiwan , South Korea ,India, Thailand , UAE ,Kuwait and Japan.USA has itself has 230 cafe at various locations such as universities , airports , malls , hospitals etc .
Au bon pain major turnaround came when group of former employee took over the management from Compass group in year 2005 and are running this corporation successfully since then.
HQ -Copley Place100 Huntington AveBoston, MA 02115Phone: 617-247-9467
The Center will also be responsible for advancing major biscuit technology platforms for the European market . It would focus basically on new biscuit products , packaging , ingredients and biscuit innovation for better nutrition .
Kraft has bought Danone s biscuit business in Europe and other countries .Its biscuit division HQ is based at Paris as an agreement with Danone
FSSAI has been constituted by govt of India through Food safety and standards act , 2006 to formulate policy , rules and guidelines for food safety and set standards for food additives and their use.
The FSSAI has prescribed penalty of Rs 10.0 lakh under the act for such manufacturers who gives misleading ads . It also recommends guideline s such where food manufacturers
Does not put advertising and communication of the food and beverages products should not be misleading or deceptive.
The advertisements should not encourage excessive consumption or inappropriately large portions of any particular food and not exploit consumers’ lack of experience or knowledge.
The code also points out that the advertisements should not undermine the role of parental care and guidance when children make food choices.
It discourages the portrayal of products as substitutes for meals, and endorsements by government agencies, professional bodies, independent agencies or individuals in a particular profession without their consent .
Are you planning to open an bakery unit . Major equipment or you can say heart of any bakery operation is the Oven from where we produce our baked products let it be cake , biscuits , cookies , wafers , buns , puffs , pizza ,pastries ------ so many other form s of bakery products . Baking is done in these ovens . You have to be careful while selecting ovens .
Criteria for selecting Oven
- Space - Check the dimensions available for the oven which can be installed in your unit . You can check the length and width of the Oven and ask manufacturer to as per our factory layout .Space required for tunnels ovens and travelling ovens are larger than smaller ovens like rack or deck ovens or Rotory oven .
- Fuel - Burners are now available for different type of fuels -eg gas , diesel oil , electrical .These burners are installed in the Bakery ovens .Check the availability and cost of the fuel before finalising the type of Oven you require
- Product - Once your have finalised your product you can approach different types of oven manufacturers for your production of cake , biscuit , pizza , biscuit ,cookies and other related products . Versatile oven can be made as per the buyer .
- Capacities - Plan your capacities for term of say 3- 5 years where you increase your production and need not run for additional ovens . Capacities helps Bakery oven manufacturers to design ovens as per the requirement
- Method of baking - Various methods of baking are popular in bakery industry eg Direct heating , Indirect heating or Hybrid Oven for combination of direct as well as indirect heating .
- Automation - Level of automation can be done as per buyers requirement .Automation in respect of burners , safety and temperatures controls can be done by the oven manufacturers.
Different Kind of Industrial Ovens
- Rack or Deck Ovens
- Rotary Ovens
- Contray Ovens
- Swing Tray Ovens
- Travelling Oven
- Tunnel Ovens
- Direct Heating Ovens
- Indirect heating Ovens
- Hybrid Oven
- Wafer biscuit oven
- Flat Steel band Oven
With competition hotting up with players like Britannia , ITC ,Priya gold inching up their market share. Parle product is exploring overseas for production unit and most likely it wold be in African continent . Parle has been exporting its products to African countries ,Asean countries , Middle eastern countries , UK ,Australia , New Zealand ,Canada and USA .Exports covers 4% of the sales volume and planning for 10% of the total sales value . Parle has already opened an production unit in Cameroon, Nepal and Bangladesh .
On domestic front Parle is involved in revamping its brands like Krack Jack , Launching new products like bourbon under Hide n Seek brands .
This factory would produce biscuit and would be sold under brand names of "Jubileenoe", "Barney", "Utrenney", "Prichuda” and ''Shokobarokko''.
Biscuit factory was largest in Moscow and was known as Bolshevik Factory .Kraft took over the factory from Group Danone biscuit operations .
Kraft Foods Inc is world second largest food company having brands like Oreo , Kraft Cheese , Philadelphia coffee,Tolberone and Milka Chocolates .
They have also asked consumers to try out private labels or non branded items which may be lower in salt content . As per surveys its has been proved that 85% consumers sticks to the brand s they buy regularly .
Consumers are asked to check the labels on packaging and buy only those products which contains less salt .
Krack Jack with a new packaging and logo . Krack Jack is the leader in salt n sweet biscuit category with 45% market share with Britannia 50 -50 coming next to it .
Krack Jack along with Parle G makes the maximum contribution to Parle sales .Krack Jack campaign is worked out by Thoughtshop, Message which is underlined is duality of life with personal anecdotes .The characters Krack and Jack would be personified by actors Swapnil and Gaurav on Tv ad s.
Normally treated water values required would be in between these values
- pH - 6-10
- TSS = 1500 mg or less
- TDS = 2000mg or less
- BOD = 1000mg or less
- COD = 3000mg or less
- Oil&Grease = 100 mg or less
- Heavy metals = 1mg or less
To treat waste water in bakeries different types of effluent treatments methods are used .Following are most used methods for waste water treatment in bakeries .
- Aerobic - Air is mixed with the waste water through blower for aeration depending upon the volume.
- Anaerobic - Air is avoided and the water is maintained in closed tank and anaerobic ( bio culture ) reaction takes place . Methane gas is generated in such reaction which can be used for heating application .
- Combination aerobic and anaerobic method: Both aerobic and anaerobic tanks are used for waste water treatment . Waste water is first passed on to anaerobic tanks here major BOD reduction is done balance reduction is done in aerobic tanks .
Waste water treatment process
Waste Water are collected in collection pits .Waste water is then transferred to oil and grease traps here oil and grease are removed and then this water is transferred to equalisation tanks ,pH correction is done here at equalisation with addition of soda flakes from here water is transferred to aeration tanks where water is subjected to pressurised through root blowers after aeration water moves to clarifiers . In Clarifiers sludge is separated from waste water and transferred to final tank with filters in between which clears water from any flocculation or impurities . This treated water is either disposed of into open drains or are loaded to tankers which then decant this water into central effluent plants of the city . Sludge are spread on drying beds and are disposed off when it becomes dry .
This treated waste water can be recycled and used in agriculture , gardening , road construction , cooling tower , wash rooms .
A good Dough conditioner should help in increasing yeast activity( provide nutrients) and should help strengthening gluten .
Few popular dough conditioners which are used in bakery industry are
Calcium stearoyl lactylate
Sodium stearoyl lactylate
Sodium stearoyl fumarate
These are further classified as
Reducing agent , Oxidising agent , Enzymes, Emulsifiers
These dough conditioners are used in small quantities . Trials should be taken before finalising brands of commercial dough conditioners .
Major bakery manufacturing industry are biscuit manufacturing , bread manufacturing ,cake manufacturing . These industry are labour intensive as automation is high in cost for bakery industry which these bakery industry avoid .Normal mid size factory would employ about 250 – 500 workers .
Bakeries in India have numerous accidents and injuries which goes unnoticed.
In India we have around small and medium bakery plants which produces various bakery products . Most the bigger manufacturer have outsourced manufacturing from Contract manufacturers , these contract manufacturers are not equipped financially to implement all necessary safety requirement .Hence it is the responsibility of the bigger player to ensure that safety standards are adhered to into these smaller plants . Safety could be further classified into personal safety, fire safety and electrical safety.
Slip, trips and falls major reasons for these are spillages all around production hall. Oil spillages and Water are the common reason. The major accident prone area is premixing where maximum spillages occurs. Slippery Tiles can also cause trips and falls
Flooring could also results in trip and fall as material handling is done through pallet trucks and trolleys in case of un even flooring the tendency of pallets and trolleys would be to upturn which again causes , hence proper flooring is required in these Plants . Kota Stone flooring is the best.
Loading and Unloading Heavy bags of sugar and wheat flour – 50 kg , 90kg bags are loaded and unloaded manually which may cause permanent damage to the Spine . Mechanical conveyors, Bucket elevators, Screw conveyors, Pneumatic conveyors or Bulk Handling system i.e. Transfer of raw material directly from tankers to Silos which eliminates manual loading and unloading.
Noise is another problem which may cause deaf ness among workers as they work continuously in area where you have continuous mechanical sound for example – Mixers , Compressors , Generators ,DG sets , Blowers of Oven , Vibratory sifters , Grinders etc . Ear plugs are the best remedy
Odour - Another important personal health safety issue in bakeries the major problems come from ammonia odour which inhaled in large quantity can cause breathing problem . Scrubber for ammonia can minimize the effect. We can arrange respirators for these workers
Dust is a unique problem for bakery units you can find Flour dust and Sugar Dust in many of bakeries. These may cause breathing problem, asthma etc .These are generated at grinders, sifters and Mixers.Explosions can occur in these sites if proper electrostatic arrestors are not provided .
Heavy Loads of machinery : There are many equipments which may cause accident due to shifting , change over for e.g. molder , cutters , Oven bands , conveyors etc . Forklifts must be employed in such factories.
Cuts and Burns: These are most common minor injuries in bakery plants. Burns at places like oven, boiler etc and heaters of packing machines and sealers .Explosion and fire has been reported from biscuit ovens from many plants. Explosion safety sheets are provided to release pressure building inside ovens.
Cuts happens when operators are not careful and attentive during process of packing of products as it involves knifes and cutters. Maintenance people normally are care less during belts. Burns may happens at pre mixing section where operators has to handle some chemicals like acids . Protective gloves are to be provided while handling hot objects and dangerous chemicals.
Asbestosis Many of these bakery factories roof sheds are made up of asbestos sheets which may cause asbestosis. Sheets to be changed to metallic sheets.
Heat is another source of health risk as workers are exposed to higher temperatures while working near ovens temperatures zooms to 55-60deg c in these zones .Ventilation and fresh air supply to be maintained in these areas.
Insulation is another dangerous material in these bakeries as ovens are insulated through these insulation hence any repair/replacement / dismantling of oven insulation requires precaution s such as workers to wear boilers suit before such jobs
Bakery industry has many inflammable materials which can cause fire hazards. Materials are following
Packaging material - Wrapper, Card board boxes (CBBS) and laminates Storages and waste are main factor of any fire.
Oven s These are main fire hazards in bakery unit
LPG /HSD/LDO – fuel storage tanks are also source of fire hazards. Safety standards have to be maintained as per Petroleum Act.
Electrical loose wiring or short circuit s can be reason for fire hazards.
Every bakery plant needs to put fire hydrant system in the factory premises to handle fire emergency .Normal fire safety inventories like fire extinguishers, smoke detectors, heat detectors should be installed in the factory area.
Electrical safety requires proper instillation of transformers, cable trays and panels in the factory
Cables needs to be insulated with no loose wiring in the factory. Maintenance of switch gears.
Proper trained electrician to be recruited for maintenance job... Proper safety loops to be designed during switchgear installation hence to protect any major damage to the electrical installation.
Eliminating risky operation through mechanization and automation, taking precaution s like safety guards, Safety interlocking. With safety audits manufacturers can avert major accident.Providing enough fire extinguishers ,exits routes , emergency lights , drills, training and signages can prevent major accidents
Most of the bakery manufacturers do not invest in the safety equipments and other protective equipments for short term benefits but which in longer term may prove counter productive .By adopting food safety programs like ISO22000, EMS ISO14000 , GMP ,HACCP and OSHA 18000 ensures that the companies are following standards procedures for safety of its personnel and property . Consumers should be aware of these standards and encourage those companies which have these standards implemented in their factories.
Dabur - Dabur is launching its product on health platform with products like Real Juice , Honey , Chavayan prash included in gift hampers . Brands promoted are aptly named Gift of Good Living
Pepsi Co - Pepsi co has come up with its offer on purchase of Pepsi, 7Up, Mirinda and Tropicana, along with gift packs of snacks brands like Kurkure, Lays and Leher Namkeen.
Coca Cola- Coca -Cola is offering digital ads on tv and radios on festivals .Consumers are lured with Coca-Cola Khushiyan Replay’ with prizes on purchase of coke bottles .Consumers can win Samsung cam corders other electronic gadgets .
Britannia- Britannia has its own range of gift packs named Shubh Kamanyien with range of assorted biscuits and cookies
Priya Gold- Priya gold has come up with gift packs items like assorted pack of cookies , butter bite biscuits , Italiano cookies ,
Parle -With festival nearing Parle products have come up with free gift packs of Hide & Seek, Milano and assorted biscuits.
Kanpur bakeries are on verge closure as the prices have spiralled out of control . Big companies and multinational have economies of scale in their favour . Competing with these big companies have become impossible and population in rural areas have shifted their loyalties towards these big companies .The state government has also discontinued the ‘compounding’ facility provided to the small bakers with more than four burners.
There was provision of mere 3-4 per cent trade tax under the compounding system while now it has risen to 12.5 per cent under value-added tax (VAT) system. Quota for small bakeries for flour and sugar has been discontinued by govt .
Smaller companies give employments to thousands of local population . Around 44 small and medium units have closed down in past four years in the city itself confirmed by UPBMA - Uttar Pradesh Biscuit Manufacturer Association .
UP govt has to take appropriate steps to prevent loosing jobs or extinction of these once prosperous bakeries .
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