PARLE - G World's Largest Selling Biscuit - Nielsen

Parle -G still  rules  the world   .Parle -G with its taste and quality has  been popular for generations of Indian  .

Parle-G, the glucose biscuit brand from Parle Products , has consolidated its position as the world's largest selling biscuit brand, says a report by Nielsen.

The study, for last year, says Parle-G has topped brands like Kraft's Oreo, Wal-Mart's private labels and Mexico's Gamesa in voulme sales to lead the 11,295-crore Indian biscuits category.

The Nielsen study adds India is the world's leading market for biscuits, ahead of the US, Mexico, China, Argentina, France, Italy, Germany, Turkey and Spain.

Source 
The Economic Times

New PET Transport Trays From Linpac For Bakery Products

Market returns  due  to damages during transit has been a major worry  for many  bakery manufacturers .Many methods like putting products into PVC trays or inserting separators , dispensers  etc  has been adopted by manufacturers . Linpac  has designed a new  PET transport to tackle this problem .

pic courtesy -Linpac

A report

 Major  Benefits  from Linpac New transport trays

* Empty trays stack together very closely, thereby reducing delivery costs
* When the trays are filled and turned through 180-degrees the rib design ensures products do not touch each other from one layer to another
* Products can be packed 40 or 60 to a box, rather than the current 20
* The increased payload in relation to volume saves on transport costs and reduces fuel consumption
* The trays are lightweight and can be recycled – offering further environmental benefits
* The robust design reduces the risk of damage during transit
* The new packaging is available in a range of colours – including black and opaque, so retailers can clearly differentiate between product ranges for consumers
* The stylish trays can be used as point-of-sale display units, as well as transport trays.

source
www.linpac.com

Dark Fantasy From ITC

Sunfeast brand of  biscuit  from ITC has recently launched its premium  cream biscuit  "Dark Fantasy "   with  chocolate and vanilla flavours . Its cream biscuit  for premium segment of biscuits priced Rs20/-  for 104 g  . ITC  have launched   Dark Fantasy biscuit to compete with Britannia s Pure magic  and Parles Hide n Seeks  premium biscuits .ITC  has now representation in all major categories of biscuits from glucose , marie ,nice , cream, bourbon and salty .

ITC  Chocofills - Innovation in biscuits

Packaging Changes From Fmcg To Cut Cost

Under  pressure  from rising prices and competitions  major fmcg  have now focusing on cost  reduction strategies  for  their product packaging . Packaging cost  is   a major cost contributor in product costing .

Few of the strategies   are

• Smaller packs  
• Smaller secondary packaging
• Alternative packing material
• Lighter packaging material
• Lesser printing
• Lesser margins  at end seals  ie reduction in cut off length s
• Pre- formed cartons and packaging boxes
• Universal packaging material and cartons for all locations

A report  published in ET

It is not just consumers who are tightening their belts in the face of runaway food inflation. Some of the country's largest consumer products companies such as Hindustan Unilever and Parle Products too are doing the same by reducing the package.


Now, reducing package has two elements: the content of the pack and the material used for making the pack.


While most consumer goods companies have periodically reduced the weight of packets to deal with increasing input costs, packaging firms are working on developing newer, cheaper packaging materials to control costs. The measures include tweaking the size and thickness of packages as well as replacing costly material with lower-cost alternatives.


"We have already deployed some lower-cost alternative packaging into the market," Tetra Pak India MD Kandarp Singh said. "For example, when the norm was for dairies to offer milk in half-litre and one-litre packs, we offered our customers a 200ml alternative in the TFA (tetra fino aseptic) pouch-shaped format and this is the alternative that is finding ready acceptance amongst consumers," he added.

 read more on
 The Economic Times

Movers And Shakers of Indian Bakery Industry

Following personalities in their own way have contributed  to   Indian Bakery  Industry ,which is  now transforming  into biggest  food processing  industry   estimated  to  be Rs 11000/- crore  and had now established its own  huge supply chain from  vendors , workers , consultants , equipment manufacturers , ingredient manufacturers , packaging design , packaging material , material handling , food safety ,pest control  bakery cafe s ,marketing and advertisement .



Nulsi Wadia  -  Took over Britannia from erstwhile  Biscuit King  Rajan Pillai . Had increased his stake in BIL  by  buying Danone ( french ) and Fontera ( New Zealand -dairy business ) shares  . Shrewd Business man  expanded Britannia s  foot print in Middle East through  buying out  Strategic Food Int llc -UAE  and Al Sallan foods -Oman .


Vinita Bali -  Guiding Britannia to robust growth  from  stagnation  . with experience in marketing through her stint  with Coca Cola and Cadburys  She  is now engaged into  diversifying this Biscuit giant into  dairy , Health and wellness beverages  market . I would like to mention  the predecessor to  Vinita Bali , Sunil Alagh was responsible for turnaround of  Britannia from  Rs 600.0 crore company to  Rs 2000 crore company


Sharad  and Vijay Chauhan  - Gained No-1  position for Parle as biscuit market leader in India . Aggressively driving  Parle distribution network and launching  new products .





Jayant Kapare  -  New entrant  to  Indian biscuit  market but with brand like  United Biscuits under his leadership is trying to establish itself  into major biscuit player .With launch of  products like cookies , cream , digestive  and Marie  in very short span  United Biscuits  is set  to give  good competition t



Nikhil  Sen - Took the challenge  to give Indian consumers something different from what has been offered till now through branding of cookies with leading   Australian firm Unibic . Mr Nikhil Sen has been an old hand  in biscuit industry as Ex -COO Britannia .




Chitrajan Dar  - Taking over from  prolific  leader in ITC food division    Ravi Navare . Marketing aggresively to get larger market share of biscuit market through launch of new products  




B.P  Agarwal - No one  ever thought that  a  small player like Priya gold would give a  tough competition to biggies of biscuit industry but through  clever marketing  and  pricing it made inroads to uncharted  rural market  thus making  Priya Gold  in Top 100 fmcg brand .



Sanjeev Kaushal - In less than a decade time Sanjeev Kaushal has made a mark in Indian bakery  equipment manufacturing   with  his company New Era Machines  and simultaneously building automation centre for these ventures through its arm New Era controls .

K.B .Kale  -  Pioneered  Biscuit Ovens in India  with his company Prima Engineering . Now manufacturing complete biscuit line  .Exporting biscuit lines to several  countries .
  

J.R  . Trivedi  - Doyen of Indian packaging machinery manufacturing . Mr JR Trivedi has developed low cost packaging machines  for Indian food processing  which can compete with imported machines on performance . Multipack  systems pvt ltd  is now exporting these  packing machines to several countries .



 Adil  Hassan and Taab Siddiqui-  Made  Harvest Gold Bread  a run way  success in  Delhi - NCR  region with in small period of time . Thus  becoming  consumers most preffered bread  in capital region dislodging Britannia and other  brands . Hence  they   proved that if  you make quality product  you can beat  the established players of the Industry .

H.T.Khorakhiwala - Established Monginis Foods and initiated indian  bakery  cafe s  in different cities . Monginis cakes/muffins cup cakes  are now availbale in  major cities  and have 250 retail shop  across India .

M. Mahadevan  -  Responsible for  setting up  bakery  retail   shop  by the name " Hot Bread " . Now expanding in different parts of world .


Anand Kripalu  -  MD Cadburys India  Now under Kraft Food Inc  would be responsible  for launching brands like Oreo biscuit  in India


Many more on regional levels 


Add your own favorites you think  have contributed to Indian bakery industry .

Process Flow chart for automated pre- baked frozen pizza manufacturing

flow chart on
bread manufacturing
biscuit manufacturing

What drives consumers for pizza

United Biscuits Targets Zero Waste To Landfill For All Its Unit

Zero  waste  from  food processing units requires efforts , technology and concerns from top management  for  sustainable growth  helping in waste reduction and environmental conservations. It covers zero emissions , zero effluent discharge and zero food waste from manufacturing unit  .In most of the cases we find that manufacturers pay for services to dump waste to landfil.  UB   has always being first  to address these issues . Great role model for  other manufacturers to take the lead .

A report .

United Biscuits (UB), makers of snacks including McVitie’s, Hula Hoops, KP, McCoy’s and Jacob’s has today announced that four of its 14 UK sites are now sending zero waste to landfill.

The sites at Hayes, Consett, Rotherham and Ashby achieved zero waste to landfill by maximising their recycling efforts, reducing the amount of waste being brought in to the business, and having any residual waste that could not be recycled normally incinerated to create energy. UB announced last year that it had achieved its target of zero food waste to landfill by 2010 a year early - and after achieving a 44% reduction in non-food waste to landfill in 2009, UB brought forward its target of zero non-food waste to landfill to 2012, from the original deadline of 2015.

With four sites now sending zero waste to landfill, and an overall reduction of 55% in non-food waste to landfill across the UK business last year, UB is well on its way to meeting its 2012 target.
Key highlights last year in UB’s programme to reduce waste to landfill include:

- Increasing recycling volumes by 19%
- Improving the recycling percentage to 95% in 2010 compared to 70% in 2009.
- Decreasing landfill volumes by 1,274 tonnes (down 55%).

Source
United Biscuits

 Not only these programs conserve resources but also save cost in operations .
Great work from United Biscuits   .Its now upto consumers  to encourage  such manufacturers  

Cookies Vs Gazak's -Winter Does Have Impact On Sales Of Biscuits

While taking my daily dose of  Gazaks( sesame mashed with jaggery)  , Raibari ( sesame with jaggery)  and Gur Ki Patti ( peanuts with jaggery) , Chikki , Til ki patti and  relishing parathas ( Indian non leavened bread with oil spread on surface )   for morning break fast  I was  wondering whether this  change of  eating habit in winter  has  any impact on  sale of  biscuits and cookies  which  are popular snacking and any time food  for millions of Indian house holds . Only  hot Pizza's have been able to hold ground as  favorite bakery product in winters for Kids .

Personally my house hold intake of baked goods does see a   change in favour  of  these winter delicacies of Gazaks , Til-Patti , Methi ke Ladoos , Gur Ki Patti  for snacking and Paranthas instead  of ever  preferred  morning break fast  sandwiches .

Talking to retailers   I found  that they all agreed to fact that the sale of biscuits and cookies have seen fall a of 5- 10%  at their stores . People prefer these seasonal products which have added  health advantage .Sales picks up only after winter is  over

Digging more into  these road side vendors  business who are seen every where during winter seasons stationed in all major localities.Preparations are done in two - three month in advance  to prepare these varieties and then distributed  to either wholesaler who sell by stacking up all these products in bags or sacks, Jars  for sale .Cart vendors  buy  these products  to sell  them  to different locality of the city .Season start from month of December and ends by  February . Selling price  for these product are  Rs 120- Rs 200 / Kg . They  claim to  make profits  in range  30 - 40%  for these product .Major raw material required are peanuts , sesame seeds , sugar and  jaggery. Products of various shape and flavour could be found with these road side vendors such  rolls , squares and triangular gazaks  with flavours of  jeera (cummins seed) ,sounf ( fennel seeds) , dessicated coconut  and dry fruits.

Many entrepreneurs  had made fortune by catching up with these trends as they pack and market these products to supermarket , mall and food stores  . Every sweet shop of repute starts promoting their own product for this season . Most of these items  are into non - branded categories except for few pan India brands such as Haldi Rams  Gazak .

 Local  biscuit and cookies manufactures have tried to cater this market with cookies with sesame seeds and peanuts . Can expect manufacturers to innovate and produce some of these  products .

Sigpack Systems AG Renamed Bosch Packaging Systems AG .

Sigpack Systems AG  was taken over  by  Bosch  in Fin year 2007-2008 . Sigpack systems  have been used by bakeries  all around world . Its packaging machine under   series of  GS , HS ,HM , HBM  are widely used by bakery manufacturer. Now named as  Bosch Packaging Systems AG .

 Bosch Company press release

Bosch Packaging Technology, a leading supplier of holistic packaging and process technology, is changing the company names of its subsidiaries Sigpack Systems AG and Paal Verpackungsmaschinen GmbH, effective February 1. Sigpack Systems AG, based in Beringen, Switzerland, will become Bosch Packaging Systems AG. Paal Verpackungsmaschinen GmbH in Remshalden, Germany will become Bosch Packaging Systems GmbH.

The renaming highlights Bosch's strategic approach to provide an even wider variety of solutions from one source. With technologies from feeding and distribution to wrapping, cartoning, handling and case packing, Bosch Packaging Systems offers a comprehensive portfolio for primary and secondary packaging.

“As Bosch Packaging Systems, both companies benefit even more from the globally renowned reputation of the Bosch brand,” explains Friedbert Klefenz, President of Bosch Packaging Technology. “The product brands Sigpack and Elematic will continue to exist under the strong Bosch umbrella. This unified market presence strengthens our position as a leading supplier of innovative, customized solutions.”

Bosch Packaging Technology, based in Waiblingen (Germany), is one of the leading suppliers of total solutions for packaging and process technology. The company develops and produces in 16 countries and distributes worldwide modules and systems for the pharmaceutical, confectionery, and cosmetics industries, as well as other food and non-food industries. The product range is rounded off with service solutions.



For more information, please visit www.boschpackaging.com.


 

Top 50 Quick Service Restaurant Brands Of America

Here is the list  of  Top 50   Quick- Service - Restaurant   Brands of  United States . Most of  which have presence across the globe with their signature products and renowned quality .Products includes sandwiches , burgers ,pizza/pasta and snacks . Ranking is for the year 2010

1       McDonald’s     ( burger)
2       Subway           (  sandwich)
3       Burger King    ( burger ) 
4       Wendy’s          ( burger )
5       Starbucks Coffee  ( snack  )
6       Taco Bell             (  mexican  )
7       Dunkin’ Donuts     (snack ) 
8       Pizza Hut         (  pizza/pasta )   
9       KFC                ( chicken  )
10     Sonic                (  burge )
11     Arby’s               ( sandwich )  
12     Chick-fil-A        ( chicken  ) 
13     Jack in the Box   ( burger   ) 
14     Domino’s           ( pizza/pasta  )    
15     Panera Bread    ( sandwich  ) 
16     Dairy Queen*     ( burger  ) 
17     Papa John’s      (pizza/pasta  ) 
18     Quiznos Subs    ( sandwich  ) 
19     Hardee’s       ( burger  ) 
20     Popeyes        ( chicken  ) 
21     Chipotle        (  mexican )  
22     Carl’s Jr.      (  burger  ) 
23     Panda Express  ( asian  ) 
24     Whataburger    ( burger )
25     Little Caesars   ( pizza/pasta  ) 
26     Church’s Chicken    (chicken )  
27     Steak 'n Shake         (burger )
28     Zaxby’s                   (chicken  )  
29     Long John Silver’s    ( seafood)    
30     Checkers/Rally’s      (  burger)
31     Bojangles’               (chicken  ) 
32     Culver’s                  ( burger )  
33     Papa Murphy’s       (pizza/pasta )   
34     Jimmy John’s           ( sandwich )  
35     El Pollo Loco           (  chicken  )  
36     Baskin-Robbins         (  snack   ) 
37     Del Taco                   (  mexican   ) 
38     CiCi’s Pizza               ( pizza/pasta)    
39     Boston Market            ( chicken  )  
40     White Castle              (  burger )
41     Sbarro                    (   pizza/pasta   )
42     Five Guys Burgers& Fries   (  burger   ) 
43     Jason’s Deli       (sandwich   ) 
44     Captain D’s        (seafood  )  
45     In-N-Out Burger            (burger)    
46     Qdoba                     (mexican   ) 
47     Cold StoneCreamery    ( snack )   
48     Krystal                        (  burger )
49     Tim Hortons                (  snack   )
50     Einstein Bros.             ( Bagels)


 source
 www.qsrmagazine.com

Consumers Paying More For Less In Fmcg Segment - Check Before U Buy !

Rising cost of raw material and ingredients with  other inputs of manufacturing like fuel price , packaging material cost , manpower cost  and fierce competition   have led   many fmcg  companies  to  reduce grammage , numbers or even size reduction for their product . Consumers are still unaware of the fact they are paying  more for less . Consumers need to check the grammage and relate it to the price before buying .


A report

Pay more for less. The trend in food items seems to have touched other products of everyday necessity too.

Mumbai-based techie Mehul Shroff for one is miffed at having to pay more for fast moving consumer goods (FMCG) such as detergents and toilet soaps even as the content of various pack sizes keeps reducing.

“A bar of soap that earlier sufficed for 15 days now lasts only 12 days. In recent months, I have noticed the size of biscuits, chocolates and instant noodles reduce dramatically while I continue to pay more for these products every few months. As a consumer, I sometimes feel cheated.”

With the cost of inputs ever on the rise, companies are struggling to protect their margins. Yet, a direct price hike to pass on the cost is ruled out as it could impact consumer sentiment. So, they are taking recourse to indirect price hike, through grammage cuts.


read more on
DNA

Wiesheu Dibas 64 Oven Wins Prestigious International Forum Design Award 2011

International  design forum ( IF  ) conducted by IF GmbH has  given Weisheu  Dibas 64 convection for  best design in product design category  for year 2011. IF  awards  are given to best design in product categories  for engineering , architecture and  other categories .

Wiesheu  ovens  are  popular ovens  in European market mainly in smaller bakery  category . Its German design and features makes it s  leading oven for bakeries . Unique  features of Dibas 64 that  it is the only baking oven in the world with the door disappearing into the oven casing at the side and furthermore convinces with its elegant, clear and timeless design unique in the industry.

With features like   double glass doors , removable racks ,halogen bulbs and complete S.S constructions  with  compact modular design makes it perfect for smaller bakeries .

 

The baking oven Dibas 64 in all its three sizes is a visual highlight in every store and perfectly emphasises the surrounding store concept and baking competence ( source : www.worldbakers.com)

for more on Wiesheu  Ovens  

visit  www.weisheuovens.com

Del Monte Offers Fruit Fillings To Indian Bakers

Indian bakers have been buying fruit cuts and fillings imported from various countries .Del Monte  is now ready to launch its new fruit filling range  for bakeries .

A report

Del Monte, a leading brand in the processed food and beverages industry in India, has launched a new Fruit Fillings range which is a vital ingredient used by the bakery and confectionery industry all over the world. The new fruit fillings range consists of the most sought after variants of Strawberry, Wild Blueberry, Raspberry, Dark Cherry and Pineapple. Del Monte Fruit Fillings cater to the growing demand for international quality inputs amongst bakers and confectioners, in terms of both small-medium businesses as well as large and established players.


In the current market scenario, the bakery industry in India is one of the largest food industries with a turnover of about Rs. 3,000 crore. Del Monte’s packaged fruit range consisting of pineapple slices, tidbits, fruit cocktail, peaches and prunes etc had created ripples of excitement in 2008 when it was launched. Del Monte’s packaged fruits have made deep inroads into the market and the brand has forged strong bonds of loyalty and partnership with B2B industry players. Now with the launch of Del Monte Fruit Fillings, bakers and confectioners can once again be assured of high quality and differentiated products and at competitive rates of Rs. 160 to Rs. 350 per kg, and distribution support in all metros and Class 1 Towns.


Del Monte Fruit Fillings contain whole fruits, picked at the peak of the season adding to the flavor and texture of the product. They are freeze-thaw stable as well as bake stable, and can be used in various bakeries, confectionery products and even as toppings for ice cream. Del Monte Fruit Fillings can be used in Cream Cakes (Gateaux), Pastries, Cold Cheesecakes, Baked Cheesecakes, Mousse & Soufflés, Fruit Filled Muffins, Fruit Cookies, Fruit Breads, Breakfast rolls, Danish pastries, and Croissants etc.

read more on
www.indiainfoline.com

How To Implement Kaizen Concepts In Bakery Manufacturing Units

Kaizen is a Japanese term which means continuous improvement . Kaizen has been religiously followed by major automobile and other manufacturing industry. Beauty of Kaizen concepts lies in bottom to top approach where people involved in process  contributes  to improvement rather than consultants hired from outside and they who with their experience implement ideas for improvement . Changes suggested could be small in nature but can contribute in improving process in many ways .

Bakeries can implement Kaizen concepts to increase productivity , reduce wastage , save cost in fuel , reduce procurement cost  and save cost in other area of manufacturing .

Companies can hire Kaizen experts to monitors project taken and familiarising employees to key concepts of Kaizen ( 5s , gemba , muda , poka yoke , kanban etc) . Cross functional teams comprising of 4-5 people ( including workers , frontline supervisors ) can be created for projects where improvement can done . Kaizen projects are written with clear cut objectives with time frame ( few days to few months ) to achieve with the results . Investment required  are calculated and mentioned , one should take small projects which require minimum cost and time during kaizen workshops .

These cross functional team are then allowed to brain storm the ideas for improvement and to list support from the management . The management then allocate some funds for these projects and decisions are taken by the Kaizen team on the spot . Once the stipulated time is over ( 5- 6 days workshop would be good enough ) Groups then declare their achievements and facts . Improvements which are achieved are then standardised and included in the system . This can be done on a regular basis which would impart creativity and sense of achievement in employees . Companies can start a news magazine show casing these results and giving recognition to people who have done these projects . Kaizen awards could also be constituted to encourage employees to come forward with innovative ideas .

Few Kaizen Concepts which could be used for improvement projects in bakeries are

5S - Tells about orderliness , cleanliness and Labels or marks for highlighting areas

Gemba - Kaizen - Importance to  area of work rather than meetings and discussions in closed rooms

Muda - Talks about waste in process

Poka Yoke - Mistake Proofing

Takt Time - Time taken to complete order

Autonomous Maintenance - Operators  does all small maintenance jobs

Kanban - System designed to reduce inventories and efficient delivery system for materials and movement of finished goods

and many more 



Areas of Improvement In Bakeries could be
* Product levels
* Process levels
* Store Management/Inventory/Receivables
* Procurement
* Finished Product
* Yield
* Labor Productivity
* Machine Productivity
* Production Planning and Delivery system
* Cost Management Information System
* Morale and safety of employees

( I would  be  highlighting few areas of improvement in coming posts in detail )

Kaizen  Concepts 

Automated Pizza Line - Video

Commercial Production Of Rice Flour Meant For Bakeries Started In Srilanka

Interesting initiatives  has been taken by Sri lankan govt  to reduce  imports of wheat or wheat flour  by promoting  rice flour  among  bakeries . This move  has been protested by bakeries.  

A report

Rice-based industries are to be promoted by the Mawbima Lanka Foundation under the patronage of the Central Bank and two state banks with the aim of encouraging industrialists to use excess rice for the production of value added products.

Bandara Industrial Services (Pvt) Ltd, Veyangoda has introduced its rice flour to the market under the brand name Healthy Fla at a ceremony held at the BMICH in Colombo on Thursday. Journalists were given an opportunity to taste rice-based food items prepared by using 'HealthyFla' at the event.

The rice flour is being milled at the Bandara Industrial Services state-of-the-art rice flour milling factory in Veyangoda. The Central Bank has provided financial assistance to set up the factory under its Viskam Loan Scheme.

HealthyFla, specially manufactured for bakery, confectionary and biscuit industry, is based on 100% specially selected best quality Sri Lankan rice varieties milled at desired temperature with latest state -of-the-art milling technology in maximum hygienic conditions, thus it contains no artificial chemicals or additives.

source
www.sundaytimes.lk

Bakery Packaging Machinery

Big Food MNC's Say No To Sugar In Jute Bag s

4,00,000  jobs could be impacted  by  refusal of    food  MNC,s companies to accept jute's bags  for  their sugar bags packaging . Indian Govt has made it mandatory for public companies ( JPMA) to use  jute bags instead  of  poly  bags  for their supplies and procurement . This is  to support ailing jute industry  which   gives jobs  to thousands workers   and farmers who grow jute . Food  companies need to install few equipments  to  screen out  foreign particles  in sugar bags . Where as Jute manufacturers  can  innovate  and  manufacture bags which would   remove objections from the food  companies.  Even plastic bags   could  bring contamination  which any case  requires  sifters , magnets an other screening equipments  to remove foreign particles .Bakery and Confectionery  manufacturers are one of the  biggest  consumers of  sugar .


A report

In a body blow to the ailing jute industry in the country, major corporates like Coca Cola India, Cadbury, Nestle India and GlaxoSmithkline have outright rejected the supply of sugar in jute bags. These firms have argued that the jute fibres are contaminating the sugar that they use for manufacture of their products.

These corporate majors, have instead opted for supply of sugar packed in plastic bags.

The snub to jute bags by these corporates has come at a time when the Jute Commissioner's Office (JCO) and the Indian sugar industry have locked horns over the availability of raw jute and production of jute bags in 2010-11.

Over the past few months since the peak sugar season started, all the four food and beverage companies have written letters in phases to the Indian Sugar Mills Association (ISMA) expressing their concern over jute sacks and favouring packing their materials in polypropylene sacks.

ISMA in turn has taken up the issue with the Union Textiles Ministry and the Jute Commissioner's Office (JCO) in Kolkata.

source
business standard

Biscuit Manufacturers Setting Up New Plants In Bihar

Bihar has been witnessing a renewed interest from national and regional biscuit manufacturers  to set up manufacturing units . Up till now few  biscuit manufacturers were present in the state but with CM  Nitish  New  Industrial policy  major players have put their money on the improved situation in the state . Britannia , Parle , Anmol , Sona  and Sabisco. have already begun their construction and installation plans .

A report

Three of the units, which are directly being set up by the companies, are coming up in Hajipur. The other unit, being set up in Muzaffarpur, is a joint venture with a local company getting the franchise of a reputed brand.

The units will generate employment of over 1,000 people.

Britannia is setting up its biscuit-making unit at Hajipur, around 25km north of Patna. The unit is likely to be operational by September this year.

It will have the capacity to produce 50,000 metric tonnes of biscuits every year and the company would invest about Rs 55 crore under this project. It would provide employment to 330 people.

Bansal biscuits, the makers of the Anmol brand of biscuits, too are setting up their unit in Hajipur. Biscuits made in this unit are likely to hit the local market in March this year. This unit would have the capacity to make 12,600 metric tonnes of biscuit per annum and would provide employment to 117 people. The company is investing about Rs 23 crore.

Another unit that is coming up in the same city is that of Sona Biscuits, the makers of the Sobisco brand. The company is investing over Rs 24 crore for setting up its unit which, after completion, would have the capacity to produce 15,000 metric tonnes of biscuit per annum. This unit is likely to become functional by March this year and it would provide employment to 219 people.

The fourth unit is coming up at Muzaffarpur, around 80km north of Patna, and this is being set up under the private-private partnership model. One Lavanya Finvest Private Limited has taken the franchise to produce the popular ParleG brand at this unit.

Britannia Vs Parle

The setting up of this unit would attract an investment of about Rs 25 crore. The unit, which is likely to start production by the end of this year, would have the capacity to produce 36,000 metric tonnes of biscuits per annum. This unit would provide employment to 434 persons.

The Bihar Industrial Area Development Authority (BIADA) has provided land for all these projects. “We processed the proposals at a very quick pace as the state government is determined to ensure that investors coming to the state face no hassles,” a highly placed source in BIADA told The Telegraph.

The source said work at all these projects are going on at the desired pace and going by the progress made so far, biscuit production in all these units would start this year itself.

source
www.news.biharprabha.com

PepsiCo Joins Kraft , UB & GSKB To Add Competiton In Indian Biscuit Market

"Decade of Biscuits " as rightly claimed  by  Nikhil Sen  , CEO  Unibic India and an old hand from Britannia  Industries ( Ex -COO) . Major Internatioal players are making beeline to untapped Indian biscuit segment  which have been dominated by two player  from long namely Britannia and Parle .  Kraft , United biscuits , GSKB ,Unibic and now Pepsi Co  have launched their product or planning to do so . Even Indian companies like  Shakti Bhog and now Marico  are planning to enter Rs 11,000 crore biscuit market  which is still dominated by unbranded products .Amul , India's  Dairy major  has  been news for its plan to explore  Indian biscuit segment . Consumers would see innovative products&packaging   as these companies would  try  to  lure  Indian consumers and garner market share .

A report

Forget cola war, PepsiCo now wants to battle it out in the Rs 11,000-crore Indian biscuits market that is getting chock-a-block with new entrants. The American food and beverages maker, which launched Aliva baked crackers in 2009, will start test-marketing oats-based premium cookies under its Quaker brand next month, two officials directly involved with the development said.

PepsiCo India is among a slew of domestic and international companies rushing to the fastest-growing processed food segment in the country, growing 20% a year, faster than noodles and potato chips. “The category will explode this decade,” says Nikhil Sen, biscuits industry veteran and MD of Bangalore-based biscuit maker Unibic India. American major Kraft Foods is expected to kick off its India foray with biscuits some time this year.


Source
The Economic Times

Flooring s In Bakery Plant

 Larger  Bakeries   have to decide upon type of flooring during  planning  stage  as  what kind of  flooring would be required for laying . Food factories have  special requirement  of flooring s due  to  hygiene and sanitation standards during process .
The floor of a food processing facility is typically exposed to all sorts of food byproducts, including fats, hot oils, dough,hot water , steam , cold water , sugar solutions, and natural food acids. Some of these substances can cause serious damage to concrete because of their corrosive nature. In addition, these contaminants can infiltrate uncoated concrete, resulting in uncontrolled growth of bacteria, ultimately degrading the processed foods purity.
        Consequently, coatings selected for application to food and beverage processing facility floors must be durable enough and thick enough to create a protective barrier that prevents contaminants from permeating the concrete substrate and ensures a hygienic surface
 
 Bakery Flooring  should meet following  parameters 

Thermal shock Resistant
Bakeries  have application which requires hot  and cold water  application hence flooring should with stand high temperatures .

Chemical Resistant
Bakeries have applications  of acids , sugar  and sanitation chemicals


Tough
Could  with stand heavy traffic from equipments  like pallet trucks , forklifts  and  trolleys .

Sanitary  and   Safe
As per approved ( state standards ) food grade flooring, slip resistant, odorless installation

Following  types of  flooring could be seen  in  Indian bakery  Plants
Marble flooring , Kota stone  flooring ,  Ceramic tiles flooring   and Epoxy  coatings .Popular among these are Kota stone ( lime stone )  and Ceramic tiles flooring . . Recommended flooring for bakeries would be epoxy coated flooring but has higher cost than other flooring .


Kota  stone  ( lime  stone )   flooring

Kota stone has advantage of toughness over  Ceramic tiles  as flooring material in bakeries . Kota stones are available in rough as well as polish finish  and could be cut into  any dimensions  but the industry standards is 22"x22"  . Thickness could vary from  25mm to 40mm . Kota  stone  could be  easily washed  number of times during cleaning of floors in bakeries


Ceramic tiles
Ceramic tiles have advantages of weight  , finish  and easy replacement s  when damaged .

Flooring types  in  International   bakery plants
Standards can be checked into USDA , FDA and NSF  Standards for floor coatings in food processing units 
Epoxy  coated  flooring , Urethanes ,Methyl Methacrylate, Poly Ureas

Industrial Safety Shoes In Bakery Plants

Safety  of  employee  should be  of prime importance to  bakery plant owners  and plant managers . Bakeries do  report accidents and safety  related incidents  in factories .Its mandatory in many countries  to provide  industrial safety shoes to its worker  who are working in risk prone areas . Workers performing  roles such  as plant maintenance workers , plumbers , electrician ,operators  and contract labours performing loading and unloading of heavy loads or equipments.Most common incidents are  electric  shocks  or  slippages in bakeries .Plant managers  should  ensure  that workers involved in above mentioned activities are provided safety shoes in regular intervals . ISO -9000 , ISO- 14000 , OSHA  and GMPS    have some or the other SOP s on workers  safety . OSHA defines safety  shoes in its  personal protectives equipments  as shoes having  heat resistant  soles and  impact resistant toes .Others with metallic insole and providing workers from electrical shocks.



Workers  requires protection  from

Heat  ( High temperatures  in oven area )
Impact or Shock (  Maintenance or Lifting jobs )
Slippery surface( Oil  and water leakages or spillages )
Electrical shocks (  Electricians ).
Chemical  s (  Mixing sections  or  cleaning operations )

Industrial safety  shoes are normally made up  good quality  leather  with  steel toe cap  in front  to save foots from heavy impact   and with Pu soles  International followed by these shoe manufacturers is  European standards for safety shoes   BS EN ISO 20345 :2004/A12007. Safety shoes   should be  comfortable , durable  and light weight .Options are available  for  workers to  choose high ankle or low  ankle safety shoes . Plant managers should get   safety shoes from  approved vendors from which  have been certified by  authorities  . Safety  shoes  can help  in bringing accidents rate in bakeries  to minimum levels .

Food Handling Gloves In Bakeries

Food handlers or operators in bakeries  more often comes into manual contact to perform activity in  pre mixing ( addition of ingredients & chemicals) ,mixing ( check dough consistency) , baking ( remove defectives ) , stacking ( packing) .Manufacturers provide workers with protective gloves to prevent cross contamination ,microbes and bacteria from handlers hand .Wearing gloves is not mandatory in most countries but still as per good manufacturing practices manufacturers provide their workers  with food handling gloves


Conventional method which most of the bakeries still use is  to provide wash basins  near to working areas  with potassium permanganate solution  to wash their hands in frequent intervals .


PVC  thin clear transparent disposable  gloves

These gloves are preferred gloves for  food handlers as its cheap in comparison to latex or vinyl gloves .Even while wearing these gloves workers should be trained to switch over to new pairs in case of damage or high perspiration in hands .One has to wash his hands and use dryer  before putting up new gloves  . These types of gloves are mostly used  where glove changing is frequently required .


Latex  disposable gloves

These gloves are required for handling of hot objects  such hot cookies while at baking section or removing defective biscuits from oven or depaning  operations , oven loading or unloading  in bakery manufacturing process.Its also used in area where workers have to handle chemicals .Latex gloves are costlier than PVC poly gloves  hence it is used only where you cannot  replace it withpvc poly gloves.These have to be washed and sanitised for multiple use .These gloves could sometimes results in rashes and itching.

Guidelines for Gloves
 

•      Wash hands properly before and after wearing or changing to a new pair of gloves
•      Use gloves that fit properly and that are designed for the task at hand
•      Change gloves whenever tasks change or whenever an employee leaves his/her workstation
•     Sneezing, coughing or touching one's hair or face with a gloved hand all require hand washing and a   new  pair of gloves
•     Because perspiration and bacteria buildup under gloves, wash hands and switch to a fresh pair periodically

Few experts  are  of the view that  gloves  are as harmful as manual contact . These gloves develops  pinholes when damaged which may not be visible by naked eyes , this may then results in bacterial contamination of hands.Workers never remove these gloves as often as required.Expert still believes the  conventional method of hand washing  to gloves

Provers In Bread Manufacturing

Proofing

Bread, Bun , Pie and Rusk  manufacturing  have unique ingredient yeast which is responsible for texture requires either time or conditions ( humid and  hot ) to act  and release gases which are trapped into dough ( leavening)  or fermentation . Various type of provers are available as per plant layout such as Box type , L type or Type , Gas  or  steam could be used for humidity and heating arrangement .It includes  gas burners , steam heaters or steam injection system .Rack type or Traveling tray type provers  are available for proving/proofing  process.Proofers are thermally insulated enclosures and. vary in size from a small box with shelving to a room. With  space  for  many  portable  bread  racks. Proofer  is  heated  by  steam  coils  or  electric  heating. Elements located inside the enclosure.



Intermediate  Prover
Intermediate provers are provided in bread manufacturing process to allow bread to relieve and recuperate from stress- strain to mechanical action on dough by  dividers and rounder . It also  gives dough to ferment during  this time and make dough soften up for  Final prover  after moulding .Its  also called relaxation prover  where it travels for few minutes in trays .



Final Prover

Dough  are  converted into elongated  cylindrical dough pieces  which are twisted  and re placed into moulds  which are greased  with emulsion or oil  for depanning . Final prover have arrangement for steam  which spread out  uniformly in  the final prover . Temperatures in Final prover  is about 38 deg c - 45 deg c. Humidity level and temperature maintained in such manner  that  yeast activity is maximum  in the final prover . Precautions need to be taken  so as to prevent  dough to rise above moulds . box or inversely the dough is left without rising . Speed of moulds travel in the prover  is either controlled through timers or through manual start and stop . Speed of travel of moulds are  to monitored with respect to rate of  dough yeast activity . Tray movement could be horizontal ( swing tray )  or  vertical ( Contray Oven ) . Approximately time for proving is  60- 75 min as per conditions . Final prover are mostly fabricated at site for large bread manufacturing  with drives and sprockets  to which racks are attached on which mould s are kept .With completion of  cycle in prover  the dough which is risen to 3/4 th mould is  then  transferred to oven for  baking .   Other popular type of prover are retarder prover . Capacities are matched with that of  Oven .

Its Boom Time For Biscuit Equipment Manufacturers In India

All major  biscuit manufacturer in India have declared their plan to go  for  major expansions.  We have been covering  news of  expansion report   for

Britannia Industries

Parle

ITC

Unibic

Ravi Foods

Anmol  Biscuit

With  many investors and foreign players  also  scouting   to enter Indian biscuit market  demands for biscuit equipments would definitely  rise .Investment in Plant and Machinery  varies from Rs 5.0 crores to more than Rs20.0  crores .These capital  equipments  are custom  made and requires  lead time varying from 16 weeks  to 24 weeks .

 With such  higher number of expansion   biscuit equipment manufacturers can expect   large orders for  biscuit equipments  such as Mixers , Ovens , Bulk Handling system , Packing machines, Grinders & Belting  . India have flourishing   domestic biscuit equipment manufacturing  industry  with few big  equipments  manufacturers who  can  claim to be producing   good  quality equipments  which caters  to organised sector of biscuit market ( 25% of total biscuit production is in  organised sector ) .Few of them  are exporting equipments  to  African , Middle Eastern Countries , Asian , Eastern European , South American countries . Most of the  biscuit manufacturers buy from these domestic  equipment manufacturers  which provide reliable and low cost equipments in comparison to  imported  equipments . Main competition for  equipment comes from  German , American and Taiwanese Equipments .Versatile Biscuit plant which can produce both Hard and Short Dough types are in big demand .Biscuit equipment manufacturers have started providing automation  solution  with PLC 's  and  Softwares  thus  increasing productivity  of  the plant .

Few of Established  Biscuit  Equipments Manufacturers are

biscuit oven

Biscuit Plant and Equipments

• New  Era  Machines
• Prima Engineering 
• Sunbeam Machines Indian P Ltd
• Sarla  Industries

 Packing Machines

• Multipack Systems Pvt Ltd 
• Khosla Packaging Machines

Bulk Handling Sytem

• Miranda Automation 
• Rieco Industries
• Indcon Projects

 Metal Detection

• Technofour Electronics P Ltd .

Grinders

•  Kaps Engineers

BAKERY BAZAR CROSSES 1.0 LAC VISITORS

Another Mile stone achieved by Bakery Bazar Blog . It has crossed 1.0 lac( 1,00,000) visitors in span of less than 24 months and is growing with 100 nos of subscriber  plus Approx  1000 daily page views . 250  comments  from visitors.

Thank U All for the support !

Vir Sanghvi On His Favorite Cookies

     Vir Sanghvi  India s Ace  political commentator  turns  his attention towards  his  favorite  biscuits and cookies . An article in HT  Brunch . Knows  a lot on  Biscuit market and trade .

Not only has it been a long time since Britannia ruled the waves, it has also been many years since Britannia ruled the Indian biscuit shelves. In my youth, Britannia and biscuits were synonymous. You had the Parle Gluco biscuit of course (apparently the largest-selling biscuit in India in that
era), but the ones that ordinary middle class families like ours chose to buy were Britannia’s versions of such British favourites as Bourbon, Marie, Thin Arrowroot and Nice (pronounced, we were told, like the city in France – not that it mattered as long as we got to eat the layer of sugar on the outside.)

I discovered later that this had to do with Britannia’s original corporate parentage (British companies with such reassuringly dated names as Huntley-Palmer) and the colonial desire to export great British brands to each corner of the empire.

Then, the Brits got taken over by Americans. Such giant conglomerates as RJR Nabisco (maker of the mighty Oreo which is to the US biscuit – sorry, cookie! – market what Coca Cola is to its soft drink sector) were placed firmly in control and the sweet old colonial brands started vanishing. Eventually, it all got very complicated with Nabisco being taken over by Wall Street bankers, Indian Britannia being sold, its new owners fighting with its new French partners etc. etc.

In any case, I am assured now that this avatar of Britannia, part of Nusli Wadia’s empire, has its own Indian identity and is so successful that foreigners try and steal its brands (Tiger biscuits, for instance). Fair enough. But two points are worth making. One: it is not the Britannia I grew up with. (But then, this is not the India I grew up in either so I guess that’s only to be expected.) And two: that the relaxation of food imports means that the shelves at my local grocer’s groan under the weight of so many imported biscuits and cookies from all over the world that the biscuits of my childhood (the great Britannia varieties) end up being relegated to the back of the shop while fancy expensive biscuits with French and German packaging occupy pride of place.

Source

All In Good Taste - Hindustan Times

Dioxin Tainted Food Scare Across EU

 Eggs  are one of the prime ingredients in   bakery products  such as Cakes , Pastries , Cookies & Buns . Dioxin scare has  affected  bakery manufacturers in a way that  retailers  have started taking off  bakery products from shelf  as reported in  UK & Ireland .It all started when Oil meant for industrial  use went as animal feed to poultries

A  report

The contaminated eggs with toxic dioxin from Germany are panicking consumers across Europe as they are suspected to have entered the UK food chain. It is understood that 14 tonnes of tainted egg product sent to the Netherlands from Germany, destined for use in goods such as pastries and mayonnaise, had been re-exported to Britain.

Earlier this week, the German authorities said up to 3,000 tonnes of contaminated feed, which are only meant for industrial use - were sent to poultry and pig farms, and that eggs from some of the farms were then exported to the Netherlands for processing. The origin of the feed contamination has been traced to a distributor of oils for animal feed production in the northern German state of Schleswig-Holstein, where oils meant for industrial use in biofuels were distributed for animal feed.

The German agriculture ministry has said that 4,709 farms were being closed as a precaution, and the suspected toxin fed chickens about 8000 were so far culled. Eight of Germany’s 16 states were affected by closure order.

The European Commission health spokesman Frederic Vincent said in Brussels that it was still unclear if those eggs contained dioxin. However, tests of other eggs from suspected farms were found to contain up to five times the EU’s limit for dioxin.

Read more on
German Dioxin-tainted Food Scare Heightens across EU

Britannia To Take Appropriate Action Against Kraft Legal suit

Britannia Industries, the maker of Tiger biscuits, today said it will take “right and appropriate action as it always has” against thelawsuit filed by US-based Kraft Foods for alleged trademark and
copyright violation of its Oreo cookie brand.In a suit filed on Tuesday in the Delhi High Court, Kraft said the
Bangalore-headquartered biscuit maker’s newly-launched Treat-O snack copied its iconic chocolate and cream-filled sandwich cookie. It alleged Treat-O, with an emphasis on O, was inspired by Oreo and Britannia also copied the specific design like florets and etchings.


Kraft has sought an injunction to prevent Britannia from manufacturing, selling, marketing or advertising any product similar to Oreo cookies. The US-based confectionery maker has also sought damages
for such violations and unfair competition to its Oreo brand of cookies.

Harish Bijoor, a brand consultant, said Kraft had indeed spent a good amount of time and dollars to build a fabulous brand, Oreo, and they will not let go of Britannia’s Treat-O lightly. “Oreo is an Oreo and in
India, it costs a lot but people do buy it. Treat-O is too close for comfort. I think Britannia may have to relook at this,” he said.

This is the second time that Britannia has entered into a legal tussle with a global food company over patent issue. Britannia had taken French food company Danone to a Singapore court, alleging trademark
infringement of its Tiger biscuit. It settled the case with Kraft after Danone sold its biscuits business to the latter.

Industry experts said the timing of the dispute was important, as Kraft after taking over Cadbury was planning to manufacture and sell biscuits in India.

Source

Read more on Business Standard

Kraft Foods' suit: Britannia to take 'appropriate action'

Story Of Hot Breads M Mahadevan

Innovation , quality  and good service  are basic ingredients for any  food business . Mr M Mahadevan learnt these traits early  in bakery business . Hot Breads has been popular bakery cafe many part of world .
A Interview with M Mahadevan published  in Finacial Express
by Sushila Ravindranath
When I tell M Mahadevan that I want to talk to him over lunch, he asks me where I would like to eat. I have a choice of over 30 restaurants and 30 bakeries co-owned by him in Chennai. The fact that I am a vegetarian makes the choice easier. I opt to meet him at Cream Center, the highly popular pure vegetarian eatery, where it is difficult to find a place if one goes late, especially during dinner time. Mahadevan, also known as 'Hot Breads' Mahadevan, is waiting for me at a corner table. He urges me to order a fruit cocktail and chooses a fresh lime and soda.
The waiters hover around us, and the restaurant manager and chef come around to say hello. Mahadevan knows them all, their names and has easy conversations with all of them. "I love food and enjoy people. So this is a natural choice of business for me," he grins. "Food has to be a passion in this business. I tell my boys, enjoy food, and cook with passion and love. To retain people is an art. My chefs are like my family members.

When I tell M Mahadevan that I want to talk to him over lunch, he asks me where I would like to eat. I have a choice of over 30 restaurants and 30 bakeries co-owned by him in Chennai. The fact that I am a vegetarian makes the choice easier. I opt to meet him at Cream Center, the highly popular pure vegetarian eatery, where it is difficult to find a place if one goes late, especially during dinner time. Mahadevan, also known as 'Hot Breads' Mahadevan, is waiting for me at a corner table. He urges me to order a fruit cocktail and chooses a fresh lime and soda.
The waiters hover around us, and the restaurant manager and chef come around to say hello. Mahadevan knows them all, their names and has easy conversations with all of them. "I love food and enjoy people. So this is a natural choice of business for me," he grins. "Food has to be a passion in this business. I tell my boys, enjoy food, and cook with passion and love. To retain people is an art. My chefs are like my family members.
Source
http://news.in.msn.com

Ads   Learn to bake delicious  cakes and pastries 

 

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Britannia Industries Sued By Kraft Food For Treat -O biscuit .

 
US-based packaged food maker Kraft Foods on Tuesday sued Nusli Wadia-owned Britannia Industries for trademark and copyright violations of its popular Oreo cookies.

In a suit filed in the Delhi High Court , Kraft said Britannia’s recently-introduced Treat-O biscuit is a copy of its cream-filled sandwich cookies.

The US firm has also sought an injunction to prevent Britannia from manufacturing, selling, marketing or advertising any product with any distinctive element of Oreo cookies.

A Britannia spokesman refused comment saying the company has not received any communication on the issue so far.

This is the second instance in four years when Britannia has been involved in a legal tussle with a multinational food company over trademark. It was, however, playing the role of a plaintiff in 2007 when it had dragged French food giant Danone to a Singapore court alleging trademark infringement of its Tiger biscuit. Subsequently, Danone ended its joint venture with Britannia and set up an independent company in India.

In its suit, a copy of which was reviewed by ET, Kraft has sought damages for infringement of trademark and copyright, passing off and unfair competition of its ‘globally reputed’ Oreo brand of cookies.

Oreo was registered in India in 1991 and is being imported and sold in the country ever since.

Kraft said the Indian bakery and dairy products maker has copied the specific design etchings, such as florets and inner rings, of Oreo cookies. The company refers to the design etchings as ‘Oreo cookie trade dress’.

“The lining on Britannia’s product, inner rings and florets and their placement on the product are identical to the original Oreo cookies,” Kraft said in the suit.

It also alleged that the brand name, Treat-O, with an emphasis on ‘O’, is inspired by Oreo.

Kraft’s lawsuit against Britannia comes at a time it is exploring options to locally manufacture and sell biscuits in the `11,000-crore Indian biscuit market.

Source
EconomicTimes

Probiotic Breads New Trend In Healthy Bakery Products

Probiotic Breads  has been innovative  attempt  to provide consumers  healthy  bakery  products.

An Old World bread-baking company and a modern-age biotech company -- both headquartered in Northeast Ohio -- have joined forces to create what they say is the first probiotic bread in North America, and probably the first such bread line in the world.
Orlando Baking Company and Ganeden Biotech are selling their new product this month only at Heinen's stores.
Until recently, probiotics in foods were generally found only in yogurt and other dairy products. The microorganisms, which contain beneficial bacteria or yeasts that help people digest dairy products and manage intestinal diseases, as well as enhance the functioning of the immune system, occur naturally in yogurt. But the live cultures couldn't survive extreme temperatures, so baking or freezing foods containing probiotics were out.

Read more on
Probiotic bread makes its debut in Cleveland | cleveland.com

Top 10 Post On Bakery Bazar In 2010

Going with   google -analytics  report  here  are   Top 10  Post  2010 .Most read and visited blog post in year 2010.

process-flow-chart-for-bread.

Indian-major-biscuit-brands.

best-plant-layout-for-biscuit-factory.

packaging-ideas-for-bakery-products.

haccp-in-bakeries.

ultra-modern-bread-plant-gardenia.

Indian-biscuit-industry-review.

harvest-gold-sucess-story-retold.

flow-chart-for-biscuit-manufacturing.

ibie-sept-26-292010-las-vegas-nevada