Why Cheap Labor Is Not Cheap For Bakeries
What drive these big companies in bakery industry for contract manufacturing and co -packer arrangement is low cost labor and cheap labor . The Co-packers ( CP ) or CMU ( Contract manufacturing units ) employs several contractors to get workers at very low salaries mostly unskilled and with low literacy rates . As workers are not aware of the legal wages these small companies make huge money out of these worker .
This is how companies cut over head cost of workers in these units as they don't pay for
No ESI ( Employee contribution from contractors or companies
No PF ( Provident Fund )deduction and contribution from the contractors or companies
No Gratuity for the workers who worked for more than five years
No Earned Leave for these workers
No Standard Over time payment
No Incentives or Bonus linked with production
No Medical or Insurance for the worker
No Uniform and Clothing Allowances .
Deduction in salaries for flimsy ground or absence
( Will State agencies look into these malpractices which are rampant in such units some of which mandatory by law payable to the workers ? )
As these workers are paid less there fore the rate of attrition is very high thus impacting the product quality and the process . Also as these workers starts searching for better opportunities or work part time doing extra jobs, which negates what ever efforts these companies have put to train them thus entering into vicious cycle of training unskilled labour all the time
Cheap labor has its own cost which companies are aware of but for profits they try to run the production with these workers .
Here are few negative results from cheap labor
Production inefficiency
High Maintenance cost due to break downs
High number of foriegn body complaints
High cost on continuous training ( few opts for no training )
More Product recalls
More consumer complaints due to defective s
Stress on supervisory personnel .
Major Accidents & Cuts
Hence it can be concluded that cheap labor is actually costlier than skilled and qualified labor . Companies should recognize this and aim for building effective and productive labor in longer run
This is how companies cut over head cost of workers in these units as they don't pay for
No ESI ( Employee contribution from contractors or companies
No PF ( Provident Fund )deduction and contribution from the contractors or companies
No Gratuity for the workers who worked for more than five years
No Earned Leave for these workers
No Standard Over time payment
No Incentives or Bonus linked with production
No Medical or Insurance for the worker
No Uniform and Clothing Allowances .
Deduction in salaries for flimsy ground or absence
( Will State agencies look into these malpractices which are rampant in such units some of which mandatory by law payable to the workers ? )
As these workers are paid less there fore the rate of attrition is very high thus impacting the product quality and the process . Also as these workers starts searching for better opportunities or work part time doing extra jobs, which negates what ever efforts these companies have put to train them thus entering into vicious cycle of training unskilled labour all the time
Cheap labor has its own cost which companies are aware of but for profits they try to run the production with these workers .
Here are few negative results from cheap labor
Production inefficiency
High Maintenance cost due to break downs
High number of foriegn body complaints
High cost on continuous training ( few opts for no training )
More Product recalls
More consumer complaints due to defective s
Stress on supervisory personnel .
Major Accidents & Cuts
Hence it can be concluded that cheap labor is actually costlier than skilled and qualified labor . Companies should recognize this and aim for building effective and productive labor in longer run
Basic Building Guidelines For Bakery Factory
When planning a layout for bakery unit or factory following building or construction guidelines to be kept in consideration
1. Adequate space for the machinery and equipments
2. Adequate Height in production hall
3.Ventilation arrangement such as windows and roof
4. Roofing Material - Metallic Sheet
5. Flooring material
6. Adequate Storage Area - Space for transport to unlaod
7.Adequate Dispatch Area - Space for transport
8 20 feet road around the premise for emergency services
9 Wash Rooms and Change rooms
10 Cold Storage Rooms
12 Waste Disposal Area
13 Fuel Storage Area
14 Drainage and water treatment plant
15 Fire hydrant system
16 Earth Quake and All weather walls
17 Passages , , Staircase Entrance and Exits
18 Mezzanine and Basements
19 Provision for further expansion
20 Air lines and water pipelines and support
21 Electrical cables and support
22 Utility area and its proximity to plant
23 Lighting Fixtures
1. Adequate space for the machinery and equipments
2. Adequate Height in production hall
3.Ventilation arrangement such as windows and roof
4. Roofing Material - Metallic Sheet
5. Flooring material
6. Adequate Storage Area - Space for transport to unlaod
7.Adequate Dispatch Area - Space for transport
8 20 feet road around the premise for emergency services
9 Wash Rooms and Change rooms
10 Cold Storage Rooms
12 Waste Disposal Area
13 Fuel Storage Area
14 Drainage and water treatment plant
15 Fire hydrant system
16 Earth Quake and All weather walls
17 Passages , , Staircase Entrance and Exits
18 Mezzanine and Basements
19 Provision for further expansion
20 Air lines and water pipelines and support
21 Electrical cables and support
22 Utility area and its proximity to plant
23 Lighting Fixtures
Industrial Mezzanine Floors - Storage Solution For Bakeries
While planning layout for bakery plant one can save space or eliminate need of additional floors through mezzanine floors in new project or in the existing set ups . Additional space can be generated in bakery production hall through fabricated mezzanine floors . Normally they are installed and fabricated in end of the production hall with access to it through staircase . It utilises empty over head space in bakery plants. Industrial mezzanine floors could be planned for
Storage of raw material
Storage of packing material
Storage of finished material
Setup Pre mixing Area for ease of feeding
Offices in bakery plant
Other material handling equipments would be require for heavy loads such as
Elevators
Fork lift s
Industrial mezzanine could cover entire production hall span or could be made for a section of the entire span .Mainly steel structures are used as frames with reinforcement made through steel beams and channel sections . Selection of these structures could be done by calculating load of items to be kept on these mezzanine .Columns are provided if the span is very large to support the structure . Handrails are provided for extra safety for safe working on these mezzanine . Pre fabricated racks and shelves could be used for storage purpose .Other material which can be used are aluminium and fibre glass.Other advantage of these Industrial Mezzanine is that it can easily dismantled or relocated to other location .
Flooring s could be of steel sheets , chequer plate or chip boards . False ceilings can used to cover the structure from under neath .
Most of the biscuit and bread factories have these Industrial mezzanine floors in one or other forms . As we need to provide enough height for production hall for better ventilation and heat dissipation .
Storage solutions - Racking
Bulk handling System
Storage of raw material
Storage of packing material
Storage of finished material
Setup Pre mixing Area for ease of feeding
Offices in bakery plant
Other material handling equipments would be require for heavy loads such as
Elevators
Fork lift s
courtesy:indiamart.com |
Flooring s could be of steel sheets , chequer plate or chip boards . False ceilings can used to cover the structure from under neath .
Most of the biscuit and bread factories have these Industrial mezzanine floors in one or other forms . As we need to provide enough height for production hall for better ventilation and heat dissipation .
Storage solutions - Racking
Bulk handling System
How Cassava Flour Helps Nigeria To Reduce Wheat Flour Import
Cassava Flour usage in bread and other bakery products have been encouraged by the local government of Nigeria .Recently a bill would be introduced into national assembly to make cassava flour induction mandatory for bread manufacturers .
Cassava plants are of two varieties -sweet and bitter varieties . Cassava flour is being used by local population to prepare their staple food .Nigeria is the largest cassava flour producer in the world.
At one side Nigerian government is promoting local flour and has increased duties on imported wheat ( levies upto 20 % )/Wheat flour( duties upto 100 % ) which would hurt the local bakeries dependent on wheat flour as prices of bakery products such as bread ,pastries and noodles would be impacted most due to high prices . HQCF ( High quality cassava flour) has been developed by IITA ( International Institute of Tropical Agriculture) . IITA claims to substitute wheat flour by 40 % of cassava flour in bread without affecting bread characteristics .
A balanced approach could save wheat flour millers and bakers which are dependent on wheat for their jobs where as cassava promotion can provide jobs to million cassava planters with saving in imports cost .Value of wheat imports per year in Nigeria is $ 252 Mn .
Cassava flours is extracted from tubers/ roots of cassava plant . The processing includes peeling/washing, drying , pulverizing and Milling .
Similar exercise has been adopted by Srilankan government by promoting Rice flour for bakery products with high import duties on wheat .
There is nothing wrong in substitution but the problem is on the ban of wheat .Let the common man in these country decide what he likes to eat .
Cassava plants are of two varieties -sweet and bitter varieties . Cassava flour is being used by local population to prepare their staple food .Nigeria is the largest cassava flour producer in the world.
At one side Nigerian government is promoting local flour and has increased duties on imported wheat ( levies upto 20 % )/Wheat flour( duties upto 100 % ) which would hurt the local bakeries dependent on wheat flour as prices of bakery products such as bread ,pastries and noodles would be impacted most due to high prices . HQCF ( High quality cassava flour) has been developed by IITA ( International Institute of Tropical Agriculture) . IITA claims to substitute wheat flour by 40 % of cassava flour in bread without affecting bread characteristics .
A balanced approach could save wheat flour millers and bakers which are dependent on wheat for their jobs where as cassava promotion can provide jobs to million cassava planters with saving in imports cost .Value of wheat imports per year in Nigeria is $ 252 Mn .
Cassava flours is extracted from tubers/ roots of cassava plant . The processing includes peeling/washing, drying , pulverizing and Milling .
Similar exercise has been adopted by Srilankan government by promoting Rice flour for bakery products with high import duties on wheat .
There is nothing wrong in substitution but the problem is on the ban of wheat .Let the common man in these country decide what he likes to eat .
Warburtons Enters Indian Naan Bread Segment
With presence of large population from South Asian countries impact of which can be found on native popualtion's food habits in that country , as recently chicken curry has been declared as second most loved food in UK. Curry Mania ---. Naan are popular bread for people from India , Pakistan , Afghanistan and Bangladesh .
source : warburtons.co.uk |
courtesy :thegrocer.co.uk |
Warburtons naan are packed in square wrapping and could be used as rolls or with several delicious toppings .
.
Warburtons naan bread are sold in two flavours - plain & garlic . It would be interesting to see whether naan breads would be as popular as Indian chicken curry .
What Are Bread Quality Parameters ?
Bread manufacturing process which involves following stages in bread processing such as
Mixing
Dividing
Moulding
Prooving
Baking
Cooling
Slicing
Packing
Following parameters need to be checked for better bread quality
Mixing
Quantity of Ingredients as per standard recipe
Quality of Ingredients as per standards
Sieving as per standards
Sequence of addition of ingredients
Mixing time
Dough temperature
Temperature of Ingredients
Yeast solution temperature
Quantity of Yeast ( Variable )
Quantity of water addition ( Variable)
Fermentation time
Dividing
Weight of Dough pieces
No of Dough balls per batch
Moulding
Moulder roller gaps
Moulder Board gap
Proving
Temperature of moulds
Temperature of Prover
Proving Timing
Humidity In Prover
Baking
Baking time
Baking Temperature
Hot bread weight
Cooling
Cooling Time
Cool Bread weight
Moisture content of bread before Slicing
Slicing
Slicing Thickness
Bread Dimensions
Packing
Coding
All these have set standards with few variables depending on temperature and humidity . Bread Qualtiy Parameters needs to be spelt out /displayed and recorded in regular intervals .Other physical features of bread which are important such as Texture , Crumbs , Color of crust etc .
Mixing
Dividing
Moulding
Prooving
Baking
Cooling
Slicing
Packing
Following parameters need to be checked for better bread quality
Mixing
Quantity of Ingredients as per standard recipe
Quality of Ingredients as per standards
Sieving as per standards
Sequence of addition of ingredients
Mixing time
Dough temperature
Temperature of Ingredients
Yeast solution temperature
Quantity of Yeast ( Variable )
Quantity of water addition ( Variable)
Fermentation time
Dividing
Weight of Dough pieces
No of Dough balls per batch
Moulding
Moulder roller gaps
Moulder Board gap
Proving
Temperature of moulds
Temperature of Prover
Proving Timing
Humidity In Prover
Baking
Baking time
Baking Temperature
Hot bread weight
Cooling
Cooling Time
Cool Bread weight
Moisture content of bread before Slicing
Slicing
Slicing Thickness
Bread Dimensions
Packing
Coding
All these have set standards with few variables depending on temperature and humidity . Bread Qualtiy Parameters needs to be spelt out /displayed and recorded in regular intervals .Other physical features of bread which are important such as Texture , Crumbs , Color of crust etc .
Select Your Laminator s As Per Requirement
Laminators are critical component of any hard dough or cracker biscuit line . Laminators are required to create dough laminates to be cut into sheets which are further reduced into leaner sheets in steps thus providing bite and texture to biscuits . Laminator's can be selected on basis of
Capacities - No of sheets per min or per hour
Dimensions - Length x width of dough sheet
Orientation - Vertical Or Horizontal
Vertical Laminator
Infeed of dough is on the top rollers placed horizontally with cutting of sheet done before small inclined conveyor on a small platform .
Horizontal Laminator
Height of the laminator is smaller than the vertical laminator with two sets of roller for lamination of dough sheet . Cutting of sheet is done on a reciprocating platform larger than the vertical laminator . Horizontal sheet larger area or space then vertical laminator .But if we consider maintenance of the laminator . Horizontal laminator are better option than the vertical laminator .Vertical laminator are installed where space is the contrain plus when dough feeding is done from different floors ie at certain height .
Smaller bakeries have Dough sheeter instead of laminators .
Capacities - No of sheets per min or per hour
Dimensions - Length x width of dough sheet
Orientation - Vertical Or Horizontal
Vertical Laminator
Infeed of dough is on the top rollers placed horizontally with cutting of sheet done before small inclined conveyor on a small platform .
Horizontal Laminator
Height of the laminator is smaller than the vertical laminator with two sets of roller for lamination of dough sheet . Cutting of sheet is done on a reciprocating platform larger than the vertical laminator . Horizontal sheet larger area or space then vertical laminator .But if we consider maintenance of the laminator . Horizontal laminator are better option than the vertical laminator .Vertical laminator are installed where space is the contrain plus when dough feeding is done from different floors ie at certain height .
Smaller bakeries have Dough sheeter instead of laminators .
Lindstrom Providing Works Wear Services To Bakeries
When it comes to personal hygienic clothing for bakery manufacturers of large to medium scale operations the options are
Providing uniforms to workers and maintaining deptts for collection ,repair and laundry services.
Providing works wear for year to the staff . Maintenance of these uniforms are done by the staff by themselves.
Engaging professional work wear providers to cater for their production /food handler clothings
All three options are practiced by medium to large bakery manufacturing units . Uniforms are part of food safety management systems and HACCP . It helps into reduction of foriegn body complaints ( FBC ) .
One company which has build business out of these needs of production facilities where food safety is of prime importance is Lindstrom.
Lindstrom works on principle of providing uniforms as per the requirement of clients from coats , aprons to work wears on rental basis with complete solution
Lindstrom works wear services includes
Mapping of needs
Delivery
Collection
Washing / Repair /Return delivery
Storage facility
For bakery manufacturers who do not want to handle uniform handling of employees are placing contracts to Lindstrom for these services . They have started this business since 2007 in India with offices at Chennai , Delhi , Mumbai and Hyderabad .
Check their site for more info
www.lindstrom.in
Providing uniforms to workers and maintaining deptts for collection ,repair and laundry services.
Providing works wear for year to the staff . Maintenance of these uniforms are done by the staff by themselves.
Engaging professional work wear providers to cater for their production /food handler clothings
All three options are practiced by medium to large bakery manufacturing units . Uniforms are part of food safety management systems and HACCP . It helps into reduction of foriegn body complaints ( FBC ) .
One company which has build business out of these needs of production facilities where food safety is of prime importance is Lindstrom.
Lindstrom works on principle of providing uniforms as per the requirement of clients from coats , aprons to work wears on rental basis with complete solution
Lindstrom works wear services includes
Mapping of needs
courtesy-lindstrom.in |
Collection
Washing / Repair /Return delivery
Storage facility
For bakery manufacturers who do not want to handle uniform handling of employees are placing contracts to Lindstrom for these services . They have started this business since 2007 in India with offices at Chennai , Delhi , Mumbai and Hyderabad .
Check their site for more info
www.lindstrom.in
List Of Indian Manufacturers Of Horizontal Flow wrap Packing Machine
Horizontal flow wrap packing ( hfw )machine is the most popular packing machine to be used in bakery industry due to its versatility to pack various bakery products. Following types of hfw packing machines are available for packing bakery products
Single feeder
Double feeder
Pillow pack
On edge pack
Pile pack
Family pack
Other classification is done as per speed of packing from 25 pkts /min to 150 pkts /min .
Hfw packing machines can adopt 1 -2 sku's through changeovers . Other solid items could also be packed through hfw . Wrapping machines pack product in bopp laminates, opp, poly films etc .
List of items which could be packed through horizontal flow wrap packing machines
Biscuits/Cookies/Bun/Bread/Cakes/Donuts/Wafer/Rusk/Chocolates/Noodles/Ice creams /Chukkies
Other non -food items which could be packed by hfw packing machines are
Bearings/Soaps/Stationery/Disposable syringe/Machine parts/Auto parts/Toys/Cotton Bandages/Pharma products/Cosmetics/Oil seals/Battery
Thus we can gauge the application hfw packing machines in the industry .
List of horizontal flow wrap packing machine manufacturers .
Multipack systems pvt ltd - Baroda
Khosla precision machines - Panchkula
New Indo Packing Machines - Delhi
Durga Packing machine - Faridabad
Sanjivani Products - Thane
Sahora Impex pvt ltd - Coimbatore
Rajasthan Packers - Faridabad
Khosla Machines pvt ltd - Mohali
Maa Vaishno machineries - Hyderabad
Gemp pack entterprise - Chennai
Ultra world wide pvt ltd - Mumbai
Swastik Packaging - Mumbai
Harshidi Indusries - Faridabad
Super -tech Packing - Faridabad
Bharat Industries - Noida
All Pack Industries - Faridabad
Unique Packaging Systems - Faridabad
Qasco Engineers - Faridabad
Shree Chamunda Micro Industries - Ahmedabad
V.K. Engineering & Co - Coimbatore
Packmach Systems - Noida
Excell Pack Machines - Coimbatore
Khushi Engineering Work - Noida
Advance & Autopack Sytems - Mohali
E.C. Packaging Pvt Ltd - Faridabad
Friends Packaging - Faridabad
Sai Dinesh Packaging Systems - Hyderabad
Deepak Engineers - Faridabad
Ganapati Packaging systems - Faridabad
Ovenman Industries Pvt Ltd - Faizabad
Packsol Industries - Thane
Corvette Technologies Pvt Ltd - Delhi
Sara Udyog - Noida
Interflex Pvt Ltd - Faridabad
S.P Engineers - Mumbai
B.M.Packing Machines - Mohali
Europack Packaging Systems -Chennai
Fill-N-Pack - Faridabad
Durapack - Chennai
Mansi Packaging Machines - Faridabad
Matrix Packaging Machines- Faridabad
Metro Star Packaging - Faridabad
Shakti Enterprise - Hyderabad
Omshree Enterprise - Nashik
Akash Packtech Pvt Ltd - Faridabad
SVM Wrapping Pvt Ltd - Mumbai
Singh Packaging Industries - Faridabad
S.P Industries - Faridabad
Uniwrap Systems Pvt Ltd - Vadodara
A.R Enterprise - Mumbai
Aden Ovens - Mumbai
Star Engg Corp - Faridabd
Gaurishankar Pattern - Mumbai
Robotech Industries - Faridabad
Trimurti Packaging - Faridabad
ABM Engineering works - Mumbai
Ladecor Systems - Mohali
Rising Industries - Kolkatta
D-tech Industries - Thane
Mangal Machines Pvt Ltd - Patiala
Indian Packaging Machineries- Faridabad
Deepankar Engineering - Ulhasnagar
Besto Oven - Mumbai
Benzler Machinery Products - Mumbai
Vijay pouch packaging machines - Faridabad
B.R.Pouch Packing Machines Pvt Ltd - Noida
Sabrish Packaging Associates - Bengaluru
Jwala Engineering Pvt Ltd - Ballabhgarh
Associate Pack tech Engineers - Ahmedabad
Shri Ancillary Industrial Machinery Pvt Ltd - Mumbai
Vishpack Machines - Nashik
Dhansa Engineers Pvt Ltd - Nashik
Stanzy Oven Equipment - Mumbai
KDR Industries - Mumbai
Basic terms and parts of horizontal flow wrap packing machine
Single feeder
Double feeder
Pillow pack
On edge pack
Pile pack
Family pack
Other classification is done as per speed of packing from 25 pkts /min to 150 pkts /min .
courtesy -Multipack systems pvt ltd |
List of items which could be packed through horizontal flow wrap packing machines
Biscuits/Cookies/Bun/Bread/Cakes/Donuts/Wafer/Rusk/Chocolates/Noodles/Ice creams /Chukkies
Other non -food items which could be packed by hfw packing machines are
Bearings/Soaps/Stationery/Disposable syringe/Machine parts/Auto parts/Toys/Cotton Bandages/Pharma products/Cosmetics/Oil seals/Battery
Thus we can gauge the application hfw packing machines in the industry .
List of horizontal flow wrap packing machine manufacturers .
Multipack systems pvt ltd - Baroda
Khosla precision machines - Panchkula
New Indo Packing Machines - Delhi
Durga Packing machine - Faridabad
Sanjivani Products - Thane
Sahora Impex pvt ltd - Coimbatore
Rajasthan Packers - Faridabad
Khosla Machines pvt ltd - Mohali
Maa Vaishno machineries - Hyderabad
Gemp pack entterprise - Chennai
Ultra world wide pvt ltd - Mumbai
Swastik Packaging - Mumbai
Harshidi Indusries - Faridabad
Super -tech Packing - Faridabad
Bharat Industries - Noida
All Pack Industries - Faridabad
Unique Packaging Systems - Faridabad
Qasco Engineers - Faridabad
Shree Chamunda Micro Industries - Ahmedabad
V.K. Engineering & Co - Coimbatore
Packmach Systems - Noida
Excell Pack Machines - Coimbatore
Khushi Engineering Work - Noida
Advance & Autopack Sytems - Mohali
E.C. Packaging Pvt Ltd - Faridabad
Friends Packaging - Faridabad
Sai Dinesh Packaging Systems - Hyderabad
Deepak Engineers - Faridabad
Ganapati Packaging systems - Faridabad
Ovenman Industries Pvt Ltd - Faizabad
Packsol Industries - Thane
Corvette Technologies Pvt Ltd - Delhi
Sara Udyog - Noida
Interflex Pvt Ltd - Faridabad
S.P Engineers - Mumbai
B.M.Packing Machines - Mohali
Europack Packaging Systems -Chennai
Fill-N-Pack - Faridabad
Durapack - Chennai
Mansi Packaging Machines - Faridabad
Matrix Packaging Machines- Faridabad
Metro Star Packaging - Faridabad
Shakti Enterprise - Hyderabad
Omshree Enterprise - Nashik
Akash Packtech Pvt Ltd - Faridabad
SVM Wrapping Pvt Ltd - Mumbai
Singh Packaging Industries - Faridabad
S.P Industries - Faridabad
Uniwrap Systems Pvt Ltd - Vadodara
A.R Enterprise - Mumbai
Aden Ovens - Mumbai
Star Engg Corp - Faridabd
Gaurishankar Pattern - Mumbai
Robotech Industries - Faridabad
Trimurti Packaging - Faridabad
ABM Engineering works - Mumbai
Ladecor Systems - Mohali
Rising Industries - Kolkatta
D-tech Industries - Thane
Mangal Machines Pvt Ltd - Patiala
Indian Packaging Machineries- Faridabad
Deepankar Engineering - Ulhasnagar
Besto Oven - Mumbai
Benzler Machinery Products - Mumbai
Vijay pouch packaging machines - Faridabad
B.R.Pouch Packing Machines Pvt Ltd - Noida
Sabrish Packaging Associates - Bengaluru
Jwala Engineering Pvt Ltd - Ballabhgarh
Associate Pack tech Engineers - Ahmedabad
Shri Ancillary Industrial Machinery Pvt Ltd - Mumbai
Vishpack Machines - Nashik
Dhansa Engineers Pvt Ltd - Nashik
Stanzy Oven Equipment - Mumbai
KDR Industries - Mumbai
Basic terms and parts of horizontal flow wrap packing machine
Indian Cookies Competes With Other Bakery Products
Apart from popular biscuits , cookies and bread which have been originated from European and American countries . Indian do have their own bakery products such as
NAN -KHATAI
KHARI
MATTRI OR MATHRI
PAPPADI
TEKHUA
COCONUT COOKIES
It has been popular items during festival and were tried even by the women folks in their kitchens . Traditionally popular among Gujaratis's, Rajasthani's .
Few of the manufacturers are now trying to encash on the popularity of these products, these are now being packaged and being branded . Frontier Biscuit factory a major home made cookies manufacturer and few other local manufacturer have now started marketing these Nan- khatai 's and Khari 's . Wide range of variety are available for nan -khatais such as elaichi,badam etc .
Even malls , supermarkets and retail chains have been promoting these Indian cookies through private labels . Indian cookies which till now have seen mostly with street vendors is gaining acceptance and are competing well with common bakery products .
NAN -KHATAI
KHARI
MATTRI OR MATHRI
PAPPADI
TEKHUA
COCONUT COOKIES
It has been popular items during festival and were tried even by the women folks in their kitchens . Traditionally popular among Gujaratis's, Rajasthani's .
Few of the manufacturers are now trying to encash on the popularity of these products, these are now being packaged and being branded . Frontier Biscuit factory a major home made cookies manufacturer and few other local manufacturer have now started marketing these Nan- khatai 's and Khari 's . Wide range of variety are available for nan -khatais such as elaichi,badam etc .
Even malls , supermarkets and retail chains have been promoting these Indian cookies through private labels . Indian cookies which till now have seen mostly with street vendors is gaining acceptance and are competing well with common bakery products .
Major Problems In Bread Production
Bread manufacturing consists of various stages and parameters which are standardize . Yeast is the main spoiler which if not handled with in set temperatures and humidity can impact Bread quality .
Excessive Volume ( Over proofed )
Small Volume ( Under proofed )
Pale bread ( Under baked )
Dark bread ( Over baked )
Open texture
Closed texture
Holes in crumb
Poor crumb colour
Coarse patches in crumb
Staling
Following aspects need to be checked for successful trouble shooting
Quality of ingredients as per standards
Quantity of Ingredients added
Addition of water( variable )
Mixing time
Standing /fermentation time
Yeast solution temp
Yeast quantity( variable )
Dough temp
Dividing weight
Moulding setting
Proving time /temp/humidity
Baking time
Baking temperature
Depending on process / ambient conditions values are standardize for above parameters
Excessive Volume ( Over proofed )
Small Volume ( Under proofed )
Pale bread ( Under baked )
Dark bread ( Over baked )
Open texture
Closed texture
Holes in crumb
Poor crumb colour
Coarse patches in crumb
Staling
Following aspects need to be checked for successful trouble shooting
Quality of ingredients as per standards
Quantity of Ingredients added
Addition of water( variable )
Mixing time
Standing /fermentation time
Yeast solution temp
Yeast quantity( variable )
Dough temp
Dividing weight
Moulding setting
Proving time /temp/humidity
Baking time
Baking temperature
Depending on process / ambient conditions values are standardize for above parameters
It's Coffee War By Biscuit Majors
Taking leaf out of huge success and popularity of coffee cafes mushrooming in cities , Biscuit major like Britannia and Parle have introduced Coffee flavored biscuits with Cappuccino Bourbon and Cafe Mocha respectively .
With ever increasing pressure from competition biscuit manufacturers are now looking for innovative ideas to differentiate their products from others thus came idea of coffee flavour to their premium products such as Bourbon for Britannia and Hide Seek choco chip for Parle .
Both are targeting youth segment for the success of these coffee flavored biscuits . Coffee flavored confectionery have already being tested in Indian market . With MNC eating up the cream segment these manufacturers have taken lead to present chocolate variant with tweak of coffee flavor . Increasing coffee chain s popularity for brands like barista , cafe coffee day,costa coffee and starbucks have also made them to take note of these development . Coffee consumption has been on rise among youth in this country and chocolate - coffee combination is established combination in baked goods in other countries .
It would be interesting to see whether other major player ITC , UB and Cadbury enters this race of coffee flavored biscuits .
Principles of Hot Melt Touch Dry Printing In Bakeries
Hot ink rolls are popular method of printing in bakeries mostly used by products which are packed by horizontal flow wrap machines and vertical form fill machines.Ink roll sizes are selected as per the sizes of characters and space utilised by the labels on the product pack . These ink rolls are placed on coders which makes contact with brass characters placed on type holders . Used to create labels such as production date , price and batch codes .Maximum rows could be of three to four of labels with pre defined size of alphabet or number . These brass characters are also of two different type as per printing arrangement of coders such as axial or radial .
Other form of printings include ink jet printing and thermal tape printing
Principle of Hot Melt Touch Dry Printing
These ink rolls are soaked and dried with printing ink which on heating releases molten ink which gets stuck into the brass character and when deposited on cool packing film solidifies are thus we get printing for packs.
These characters then creates prints on pre set coding space for labels . Ink rolls are of different sizes depending on application and no of characters needs to be printed some popular sizes are 36 mm x32 mm , 40 x32 mm , 38 x32 mm . Colors of Ink rolls also varies as per requirement you can get black,green,red and white ink rolls .Quality of Ink rolls are classified as per no of impression or life on ink rolls . Depending on the usage the no of impression for normal ink rolls . On average it should have life of something between 80,000 to 100,000 impression .
Cost saving ideas on Ink Rolls
- Recycle used ink rolls through dipping these used rolls into ink and then drying it to be ready for re use.
- Cutting the ink rolls in middle are placing these part with reversed side .
Please check the quality of print before you implement these ideas .
Used Bakery Equipment On Sale - Madurai
Following equipments are available for sale , Interested people can contact to the below mentioned details .
NAME = Lakshmi Palanikumar
COMPANY_NAME = Sree chakra hotels private limited
EMAIL = ranipalanikumar@yahoo.com
ADDRESS = 1,vinayagar nagar, madurai 625020
TEL/MOBILE = 9344151600,9843145511
CITY_/COUNTRY = India
TYPE_OF_PRODUCT = Bakery Machinery ....All machineries for sale
BUY_/SELL = SELL
DETAILS = Oven,Spiral Mixture, Cake mixture, work tables, moulds, deep freezers, bread slicers, puff dough sheeter, mini ovens, weighing scales elecronic, weighing scales mechanical, exhaust fans, refrigerated display counters, racks and stands, tables and chairs, pedestal fans, air conditioners, and all related equipments for bakery
NAME = Lakshmi Palanikumar
COMPANY_NAME = Sree chakra hotels private limited
EMAIL = ranipalanikumar@yahoo.com
ADDRESS = 1,vinayagar nagar, madurai 625020
TEL/MOBILE = 9344151600,9843145511
CITY_/COUNTRY = India
TYPE_OF_PRODUCT = Bakery Machinery ....All machineries for sale
BUY_/SELL = SELL
DETAILS = Oven,Spiral Mixture, Cake mixture, work tables, moulds, deep freezers, bread slicers, puff dough sheeter, mini ovens, weighing scales elecronic, weighing scales mechanical, exhaust fans, refrigerated display counters, racks and stands, tables and chairs, pedestal fans, air conditioners, and all related equipments for bakery
Contract Manufacturing In Bakery Industry -Win -Win Arrangement
contract manufacturing in bakery
Have you wondered that the biscuit pack or the bread in the poly bags are manufactured by outsourced companies and not produced by the principal brand or the manufacturer for which you have paid for .This arrangement for contract manufacturing is a win-win arrangement between the large companies with small to medium contract manufacturers . For your information all major bakery brands have their Co Packers ( CP ) or contract manufacturing unit ( CMU ) spread across the geography of country . CMU could be as large as 50- 60 units affiliated to major brands .This is also the best method to test regional markets by large multinationals in any country thus avoiding large investment and infrastructure and making a quick exit in case of failure of not making any inroads in the market segment .
Major Advantages of Large Companies from engaging Contract Manufacturers are
1. No large investment in infrastructure
2. No major commitment for labour /workforce
3. No major legal compliances and liason for legal from their side
4. Can start operations in short span with cmu in any defiecient market
5. Easy exit
6. Can have advantage such as easy backward integration if possible with facility with the cp
7. Cost saving s in terms of salaries and emoluments
8. Inventories with cmu
9. Trials and development can be taken with cmu's
Advantage for Contract Manufacturers
1. No expense on building brands
2. Steady income and low risk on investment
3. No marketing and brand building investment
4. No need have large sales force
5. No need for procurement department
6. With low investment and various financial arrangement with principals
7. Logistic and transportation inward/outward to be arranged by principals
8. Can build facilities alongwith plant for backward integration and earn additional income.
9. Can promote own brand with idle capacity
10.Consumer and customer issues with principals
11.Gets technical expertise with help of principals
12 .Raw material/packing material arranged by principals as per their standards
Following entities enter into contract manufacturing
Large manufacturers and brands
Major Super markets and Malls
Private enterpreneurs
New entrant in segments
All Major brands of bakery have network of contract manufacturers who produce s products as per the principals specification /standards /recipes . Quality is monitored by representatives of principals based at contract manufacturing units . Technical help and developments are taken care by the principals . Machinery can be leased or supplied on bailment to cmu's. Principals enters into contract with certain conversion rates per unit of product taking into account following cost
Labour cost
Fuel/electricity cost
Maintenance cost
Penalties or deductions are worked out for negative material variance if cmu or cp fails to produce as per standard output .
Have you wondered that the biscuit pack or the bread in the poly bags are manufactured by outsourced companies and not produced by the principal brand or the manufacturer for which you have paid for .This arrangement for contract manufacturing is a win-win arrangement between the large companies with small to medium contract manufacturers . For your information all major bakery brands have their Co Packers ( CP ) or contract manufacturing unit ( CMU ) spread across the geography of country . CMU could be as large as 50- 60 units affiliated to major brands .This is also the best method to test regional markets by large multinationals in any country thus avoiding large investment and infrastructure and making a quick exit in case of failure of not making any inroads in the market segment .
Major Advantages of Large Companies from engaging Contract Manufacturers are
1. No large investment in infrastructure
2. No major commitment for labour /workforce
3. No major legal compliances and liason for legal from their side
4. Can start operations in short span with cmu in any defiecient market
5. Easy exit
6. Can have advantage such as easy backward integration if possible with facility with the cp
7. Cost saving s in terms of salaries and emoluments
8. Inventories with cmu
9. Trials and development can be taken with cmu's
Advantage for Contract Manufacturers
1. No expense on building brands
2. Steady income and low risk on investment
3. No marketing and brand building investment
4. No need have large sales force
5. No need for procurement department
6. With low investment and various financial arrangement with principals
7. Logistic and transportation inward/outward to be arranged by principals
8. Can build facilities alongwith plant for backward integration and earn additional income.
9. Can promote own brand with idle capacity
10.Consumer and customer issues with principals
11.Gets technical expertise with help of principals
12 .Raw material/packing material arranged by principals as per their standards
Following entities enter into contract manufacturing
Large manufacturers and brands
Major Super markets and Malls
Private enterpreneurs
New entrant in segments
All Major brands of bakery have network of contract manufacturers who produce s products as per the principals specification /standards /recipes . Quality is monitored by representatives of principals based at contract manufacturing units . Technical help and developments are taken care by the principals . Machinery can be leased or supplied on bailment to cmu's. Principals enters into contract with certain conversion rates per unit of product taking into account following cost
Labour cost
Fuel/electricity cost
Maintenance cost
Penalties or deductions are worked out for negative material variance if cmu or cp fails to produce as per standard output .
Rusk Manufacturing Process Flow Chart
Rusk manufacturing process consists of two stage baking where in the first baking stage is more like bread manufacturing and 2nd stage baking consists of tunnel ovens for large volume or rack ovens for smaller volumes .
Major Indian Bakery Equipment Manufacturers
Indian bakery market is estimated to be Rs 12000 crore and is increasing by 10 -15 % per year . Major international brands have started investing in manufacturing bases . To cater to this huge surge in bakery segment major Indian equipment manufacturers have also increased their production .
Indian bakery equipment manufacturing is in its nascent phase .Investment and R&D inputs are very low .Quality and service level are far below world class. Automation is key to new technologies which would help Indian bakeries to compete with international players .Still few companies have marked their presence in Bakery Industry. Few of them are listed below
OMORI INDIA PVT LTD ( PREV MULTIPACK )
NEW ERA INDUSTRIES
SARLA INDUSTRIES/VIVEK ENGINEERS
NECON
PRIMA ENGINEERING
KAPS ENGINEER
TECHNOFOUR
MIRANDA AUTOMATION
CS AEROTHERM
PRITUL
AIFSO
SEPERATION ENGINEERS
NARI WIRE
ROSHAN INDUSTRIES
APPLE MACHINERY
SOHAL ENGINEERS
MANGAL ENGINEERS
SEPERATION ENGINEERS
K DHARMALINGM
There are numerous opportunities for bakery equipment manufacturers to produce
equipments which can compete for international markets .
AMF Bakery Systems - World Major Bakery Equipment Manufacturer
AMF Bakery Systems are world leaders in providing bakery equipments and solutions for bread , bun and soft rolls manufacturing units across the globe . Its also popular for customer specific packaging solutions . AMF which is now almost a century old organisation are known for technological superior products and service . AMF has presence in almost all the continents such as North -South America , Middle East and Africa , Asia , Europe and Australia / New Zealand .
The product line includes
Dough Systems
Make up systems
Pan and product handling system
Proofing and Baking system
Product cooling systems
Packaging systems
Basket and Distribution systems
Automation
Works with affiliate companies like Baketech , Tromp bakery equipments and IIM .
Head Office at
2115, West Laburnun Avenue , Richmond , Virginia 23227 , US
AMF have regional head office at Canada , UK , Singapore and China.
For more info visit
www.amfbakery.com
The product line includes
Dough Systems
Make up systems
Pan and product handling system
Proofing and Baking system
Product cooling systems
Packaging systems
Basket and Distribution systems
Automation
Works with affiliate companies like Baketech , Tromp bakery equipments and IIM .
Head Office at
2115, West Laburnun Avenue , Richmond , Virginia 23227 , US
AMF have regional head office at Canada , UK , Singapore and China.
For more info visit
www.amfbakery.com
IBA Munich 2012
IBA Munich 2012 - Germany is schedule to open on september 16 - 21 , this year . IBA is one of the largest trade event covering bakery and confectionery business in the world . This events is hosted every 3 year with help of German bakers confederation and the organisers GHM . Its held alternatively at Munich or Dusseldorf.Around 123,000 sqmtr area would be used to show the best of baking techonology , ingredients , packaging , machinery and equipments at Messe München, Germany. Bakery s Industry largest trade exhibition of the world is a must for any one related to bakery business or industry . Major equipment and machinery manufacturers are present with their latest technology . Other related seminars and workshops related to bakery and confectionery are also planned .
IBA s main attraction are
Huge potential for B2B opportunities
Innovations and latest technology are displayed
Energy efficient and environmental freindly technology displayed
Information on bakery related subjects a s food safety , ingredients , additives , Hygiene , packaging are available in form of workshops , seminars and forums .
New bakery products and categories ( which includes other confectionery items )
Main attraction for IBA -Munich would be the iba- cup which is presented to the top team of bakers which bakes the best bakery or confectionery product .
Items displayed at IBA trade fair
Ovens , Mixers , packaging machines , bagging machines , bakery and pastry making machines , Confectionery equipments and accessories ,pasta and pizza making machines , Ice cream making machines ,refrigeration , fermenting , air conditioning equipments , coffee making machines ,ice cream manufacturing , hygiene and cleaning equipments , raw material , food additive , IT service and software . Must visit trade fair for people in bakery industry and is highly recommended from us .
Sectors represented are : bakery , catering , hote and restaraunt equipments , hygiene and cleaning equipment , baking craft , confectionery , raw material , technical journals on these subjects
Location
Messe München
Am Messesee 4
81823 Munich, Germany Tel: +49 (0)89 94920720
Fax: +49 (0)89 9499720729
For more on IBA -Munich
Visit : www.iba.de
IBA s main attraction are
Huge potential for B2B opportunities
Innovations and latest technology are displayed
Energy efficient and environmental freindly technology displayed
Information on bakery related subjects a s food safety , ingredients , additives , Hygiene , packaging are available in form of workshops , seminars and forums .
New bakery products and categories ( which includes other confectionery items )
Main attraction for IBA -Munich would be the iba- cup which is presented to the top team of bakers which bakes the best bakery or confectionery product .
Items displayed at IBA trade fair
Ovens , Mixers , packaging machines , bagging machines , bakery and pastry making machines , Confectionery equipments and accessories ,pasta and pizza making machines , Ice cream making machines ,refrigeration , fermenting , air conditioning equipments , coffee making machines ,ice cream manufacturing , hygiene and cleaning equipments , raw material , food additive , IT service and software . Must visit trade fair for people in bakery industry and is highly recommended from us .
Sectors represented are : bakery , catering , hote and restaraunt equipments , hygiene and cleaning equipment , baking craft , confectionery , raw material , technical journals on these subjects
Location
Messe München
Am Messesee 4
81823 Munich, Germany Tel: +49 (0)89 94920720
Fax: +49 (0)89 9499720729
For more on IBA -Munich
Visit : www.iba.de
Common Food Allergens In Manufacturing
Food Allergy can be defined as immunological response to proteins to which body release large amount of histamines.
Few are regular allergens which results into common allergies in masses and every food manufacturers have to identify these allergens so as to take preventive measure against these allergens being passed out the consumers .
Peanut and derivatives, (e.g. protein, oil)
Tree nuts and derivatives, (e.g. protein, oil)
Milk and derivatives (lactose, milk protein, etc.)
Egg and derivatives
Fish and derivatives
Shellfish and crustacean (shrimp, lobster,prawns..)
Cereals (wheat, rye, oats, barley)
Soy and derivatives, (e.g. lecithin, protein, oil)
Sesame seeds and derivatives, (e.g. protein, oil)
Sulphites > 10 mg/kg (in the ready to eat product)
Peas and derivatives only for Nordic
Mustard
Even small dosage of allergen such as 5-7ppm could trigger allergic reactions and result into following reactions
Rash, hives, cough, shortness of breath,tightening of throat, wheezing, swelling, nausea, stomach cramps in some serious cases sudden drop of blood pressure ,unconciousness and death
Hence its important that manufacturers /suppliers understand the importance of labeling
Few are regular allergens which results into common allergies in masses and every food manufacturers have to identify these allergens so as to take preventive measure against these allergens being passed out the consumers .
Peanut and derivatives, (e.g. protein, oil)
Tree nuts and derivatives, (e.g. protein, oil)
Milk and derivatives (lactose, milk protein, etc.)
Egg and derivatives
Fish and derivatives
Shellfish and crustacean (shrimp, lobster,prawns..)
Cereals (wheat, rye, oats, barley)
Soy and derivatives, (e.g. lecithin, protein, oil)
Sesame seeds and derivatives, (e.g. protein, oil)
Sulphites > 10 mg/kg (in the ready to eat product)
Peas and derivatives only for Nordic
Mustard
Even small dosage of allergen such as 5-7ppm could trigger allergic reactions and result into following reactions
Rash, hives, cough, shortness of breath,tightening of throat, wheezing, swelling, nausea, stomach cramps in some serious cases sudden drop of blood pressure ,unconciousness and death
Hence its important that manufacturers /suppliers understand the importance of labeling
Sieves Sizes For Wire Mesh Used In Bakeries
Most of the bakeries have installed FSMS in one form or the other, most of these companies have opted for ISO 22000 , HACCP , BRC and others . Sieving of ingredients have been declared by most of the bakeries as the most critical control point ( CCP ) . I have just tried to give you few mesh sizes which are used in various plants . Every plants has its own standards .
Given are the most estblasihed sizes of wire mesh used in bakeries.
Flour - 30 -40
Sugar - 10-14
Chemicals - 24 mesh
Palm oil - 40 mesh
Ingredient s - 12-16 mesh
Water - 100 mesh
Butter - 30-40 mesh
Cocoa / Chocolate powder - 12-16 mesh
SMP - 30-40 mesh
Yeast Powder - 24 mesh
GMS powder - 24 mesh
Liquid Glucose - 14 -16 mesh
Winkies Swiss Roll
Winkies Swiss Rolls are now available off the shelf in Delhi market .Swiss Rolls are available on local bakeries but to produce and market it nation wide is another game all together however this company "Dream Bake Pvt Ltd" has launched swiss rolls by the name " Winkies ", packed in cardboard tubes.
Swiss Rolls were tried by Britannia in 1995 -1997 but not with success and was called off . Swiss Rolls are popular abroad .
Read more swiss rolls in India .
http://bakerybazar.blogspot.in/2009/07/britannia-s-failed-brands-and-products.html
Top 10 Baking Blogs
I just wanted to compile top 10 baking blogs on internet for which I surfed major search engines and blog ranking sites
Here are the top 10 blogs on baking
David Lebovitz
The Fresh Loaf
Baking Bites
Cake Journal
Cupcakes Take The Cake
Recipegirl.com
Bake or Break
Cake Spy
CupCake Project
Savory Sweet Life
Other popular websites on baking
Joyofbaking.com
epicurious.com
allrecipes.com
verybestbaking.com
veganbaking.net
Check them out for tasty , mouth watering and refreshing recipes
Here are the top 10 blogs on baking
David Lebovitz
The Fresh Loaf
Baking Bites
Cake Journal
Cupcakes Take The Cake
Recipegirl.com
Bake or Break
Cake Spy
CupCake Project
Savory Sweet Life
Other popular websites on baking
Joyofbaking.com
epicurious.com
allrecipes.com
verybestbaking.com
veganbaking.net
Check them out for tasty , mouth watering and refreshing recipes
Bergen Cookies
Apetite for imported biscuits has not died even with onslaught of international biscuits flooding Indian markets such as Oreo , Mcvities , Munchies , Tiffany etc .
Bergen cookies are all over the malls , super market and retailers in Delhi . Wrapped in attractive packaging with cookies in trays . What attracts the consumer is the size of the ring shaped with sugar sprinkled on top of cookies and laced with exotic designs . The packs were made in Poland.
Bergen cookies are all over the malls , super market and retailers in Delhi . Wrapped in attractive packaging with cookies in trays . What attracts the consumer is the size of the ring shaped with sugar sprinkled on top of cookies and laced with exotic designs . The packs were made in Poland.
Parameters For Sugar In Bakery
Sugar is among the major ingredients of all bakery products . Important parameters which bakers should check about the sugar are
Particle size
extraneous matter
color
moisture
sucrose
water insolubes
sulphated ash
heavy metals
preferably manufactured by vacuum pan process
Particle size
extraneous matter
color
moisture
sucrose
water insolubes
sulphated ash
heavy metals
preferably manufactured by vacuum pan process
Daily Production Report In Bakery
So you are handling bakery operations then you need to have daily production report first thing you look for on your desk . Now days most the bakeries rely on ERP software which collects all the vital information for daily production . Smaller or conventional bakeries still have report presented in excel sheets from their executives
Here are the important elements which makes a complete daily bakery production report
Production - ( loaves / numbers/cbbs/ kgs / tonnes )
Mixings - Number of mixings
Labour - Numbers / labour hours/overtimes/ Labour efficiency
Fuel - Ltrs / unit of production
Electricity - Kwh Units
Defective or wastages - %
Dispatch or sales
Dividing Weights
Packet Weights
Quality Index Score
Stocks - Opening and Closing for important raw material
Finished Good Stock
Available hours
Break downs - %
Gaps - In hours
Above are few important elements of any bakery production report .These could provide the complete picture of operations and on which deviations and shortfalls can be discussed and means to achieve the target production in bakeries .
Softwares like SAP and Oracle helps in getting information on mouse click .
Here are the important elements which makes a complete daily bakery production report
Production - ( loaves / numbers/cbbs/ kgs / tonnes )
Mixings - Number of mixings
Labour - Numbers / labour hours/overtimes/ Labour efficiency
Fuel - Ltrs / unit of production
Electricity - Kwh Units
Defective or wastages - %
Dispatch or sales
Dividing Weights
Packet Weights
Quality Index Score
Stocks - Opening and Closing for important raw material
Finished Good Stock
Available hours
Break downs - %
Gaps - In hours
Above are few important elements of any bakery production report .These could provide the complete picture of operations and on which deviations and shortfalls can be discussed and means to achieve the target production in bakeries .
Softwares like SAP and Oracle helps in getting information on mouse click .
Good Day - Brand Going Strong
Good Day Cookies from Britannia Industries is second largest brand of biscuit sold in India the sales turnover is estimated to be Rs 1500 crore . This single brand of biscuit is second most popular brand after Parle - G and is still growing with new set s of packaging and flavor . It started the concept of Indulgence in biscuit industry .
It all started with Britannia team launching indulgence biscuits market in 1986 where people were either have been fed with glucose varieties or some type of cream biscuit from local bakeries . Good day bridged the gap of these two varieties . Cookies were only available with local bakers Britannia grabed this opportunity and launched nation wide packed cookies and aptly named it Good day . The butter variety hit the bulls eyes and was instant hit with the masses . Later it had new avatars with pista , cashew and chocolate version .
Crispy and crunchy cookies was lapped by all and rest is the story . Britannia under pressure from high cost of ingredients have changed its recipe and prices but still Good Day cookies are favorite for every one .
Read more on Good Day brand as told by Mr Alagh former CEO of Britannia -The man responsible for the success of Good Day Brand
It all started with Britannia team launching indulgence biscuits market in 1986 where people were either have been fed with glucose varieties or some type of cream biscuit from local bakeries . Good day bridged the gap of these two varieties . Cookies were only available with local bakers Britannia grabed this opportunity and launched nation wide packed cookies and aptly named it Good day . The butter variety hit the bulls eyes and was instant hit with the masses . Later it had new avatars with pista , cashew and chocolate version .
Crispy and crunchy cookies was lapped by all and rest is the story . Britannia under pressure from high cost of ingredients have changed its recipe and prices but still Good Day cookies are favorite for every one .
Read more on Good Day brand as told by Mr Alagh former CEO of Britannia -The man responsible for the success of Good Day Brand
Indulgence over 25 years- news story in the hindu
Sandwich Biscuit In Single Pouch
Strolling in suburban area of Bangalore I could lay my hand on single sandwich biscuit packed in pouches similar to snack pouches displayed at various retail shop . The concept was selling bigger size cookies or single serving for the consumer on go should have a market , its just reverse of companies promoting smaller pouches with 2-3 biscuits for price tag of Rs 5/-.
The product has been marketed by INBISCO India Pvt Ltd , Chennai with parent company INBISCO PT MAYORA INDAH Tbk , Indonesia . Its being marketed by the brand name " Danisa" with Choco Milk Flavor and with attractive packaging .
The product has been marketed by INBISCO India Pvt Ltd , Chennai with parent company INBISCO PT MAYORA INDAH Tbk , Indonesia . Its being marketed by the brand name " Danisa" with Choco Milk Flavor and with attractive packaging .
Automation In Bread Plant
Indian bread plants in majority are labour dependent with most of the process done manually its high time that manufacturers think of automating the whole proces or in parts to eliminate
dependence on labour
eliminate waste
have consistent quality
to eliminate human errors
increase productivity
safety
In ingredient section automatic feeding to mixer with help of bulk handling , load cell based weigh hoppers and pneumatic or screw conveyors ( flour , fat, chemicals and sugar )
Auto greasing of moulds
Direct feeding of dough sticks from moulder to moulds
Auto stamping of dough sticks .
Auto Lidding and De lidding for prover and baking oven
Auto loading and unloading of moulds into prover and oven
Auto depanning of breads from moulds
Direct feeding to slicers from spiral conveyors
Control cooling
Automatic packing with direct feeding to packing machine
Automatic twist n tie or wrapping in packing
Automatic loading of packed bread in plastic trays .
Direct loading to containers with conveyors
Grinding for sliced bread waste to recycle
dependence on labour
eliminate waste
have consistent quality
to eliminate human errors
increase productivity
safety
In ingredient section automatic feeding to mixer with help of bulk handling , load cell based weigh hoppers and pneumatic or screw conveyors ( flour , fat, chemicals and sugar )
Auto greasing of moulds
Direct feeding of dough sticks from moulder to moulds
Auto stamping of dough sticks .
Auto Lidding and De lidding for prover and baking oven
Auto loading and unloading of moulds into prover and oven
Auto depanning of breads from moulds
Direct feeding to slicers from spiral conveyors
Control cooling
Automatic packing with direct feeding to packing machine
Automatic twist n tie or wrapping in packing
Automatic loading of packed bread in plastic trays .
Direct loading to containers with conveyors
Grinding for sliced bread waste to recycle
Metallic Conveyors In Bakery
Conveyors are life line of bakeries , these conveyors performs numerous functions right from material handling to , transfer , process , loading and unloading . Conveyors in bakery could be of two basic categories web conveyors or metallic conveyors
Major metallic conveyors are
Chain conveyor
Basic conveyor made of simplex , duplex , triplex chains as per the load on it . These are simplest form of material handling conveyors in bakeries where moulds are being transferred from different section s such as proving to baking and return . Consists of chain , sprockets , supporting guides and drive rollers with motors
Slat conveyor
Slat conveyor are improved version of these chain conveyors where slat elements are joined together with pins and the sprockets drives these conveyors through links . basic elements are sprockets , slats , sprocket and drive . Used to transfer moulds from proving to baking and return .
Wire mesh conveyor
Used in tunnel ovens across the bakery units made up of mesh with different widths and mesh sizes as per product requirements . Biscuit Industry are the major consumers for wire mesh type of conveyors .
Flat steel bands
Few items requires complete flat surface for movement and baking simultaneously in bakery unit for such products flat steel bands are used as conveyors for e.g cakes , swiss rolls and cookies .
Major metallic conveyors are
Chain conveyor
Basic conveyor made of simplex , duplex , triplex chains as per the load on it . These are simplest form of material handling conveyors in bakeries where moulds are being transferred from different section s such as proving to baking and return . Consists of chain , sprockets , supporting guides and drive rollers with motors
Slat conveyor
Slat conveyor are improved version of these chain conveyors where slat elements are joined together with pins and the sprockets drives these conveyors through links . basic elements are sprockets , slats , sprocket and drive . Used to transfer moulds from proving to baking and return .
Wire mesh conveyor
Used in tunnel ovens across the bakery units made up of mesh with different widths and mesh sizes as per product requirements . Biscuit Industry are the major consumers for wire mesh type of conveyors .
Flat steel bands
Few items requires complete flat surface for movement and baking simultaneously in bakery unit for such products flat steel bands are used as conveyors for e.g cakes , swiss rolls and cookies .
'Snackuits' Britannia s answer to healthy snacks
Britannia Industries one of the largest bakery manufacturer in India is trying to increase its share in snacking business which has market turnover of Rs 7000/ - 10000 /crores . Early entrant to this market have been Pepsi co with Aviva and Parle Hippo .
Britannia has launched new variants to its power brand 50-50 with flavors like " Swiss Cheese & Chilly", "Chinese Hot & Sweet" and " Italiano Pizza". These variants are mainly targted towards indian housewives for their penchants for snacks . Britannia would offer these baked snacks with healthy tag of zero transfat product. Media and tvc have been planned would be released soon .Snackuits aptly reminds consumers for snacks which are baked as biscuits.Other product which Britannia has launched in this category are "Time pass" and "Nutrichoice" . "Time pass" poppable spicy snacks are being tested in different regions . "Maska - chaska "was instant hit with youth for its unique flavours which was extension of brand 50 -50. Snackuits are being marketed in North , East and West region at present . Price tags for snackuits are being kept as Rs10/- for 30 gm pack and Rs 20/- for 50gm pack .
Its worth to note that snacking market is being estimated to be 20% for coming years . Britannia with increasing competition has made moves to diversify into other popular food segments-.Ready- to- eat , dairy and snacking .
Britannia has launched new variants to its power brand 50-50 with flavors like " Swiss Cheese & Chilly", "Chinese Hot & Sweet" and " Italiano Pizza". These variants are mainly targted towards indian housewives for their penchants for snacks . Britannia would offer these baked snacks with healthy tag of zero transfat product. Media and tvc have been planned would be released soon .Snackuits aptly reminds consumers for snacks which are baked as biscuits.Other product which Britannia has launched in this category are "Time pass" and "Nutrichoice" . "Time pass" poppable spicy snacks are being tested in different regions . "Maska - chaska "was instant hit with youth for its unique flavours which was extension of brand 50 -50. Snackuits are being marketed in North , East and West region at present . Price tags for snackuits are being kept as Rs10/- for 30 gm pack and Rs 20/- for 50gm pack .
Its worth to note that snacking market is being estimated to be 20% for coming years . Britannia with increasing competition has made moves to diversify into other popular food segments-.Ready- to- eat , dairy and snacking .
Parameters For Fat As Ingredient In Bakery
One of the major ingredients in bakery product is fat . Fat could be used as palm oil , palmolien , hydrogenated vegetable oil and others
To use fat and oils following parameters are to be checked it varies from product to product and countries to countries .
moisture percentage
peroxide value
butryo refractometer reading or refractive index
Iodine value
saponification value
oelic acid
unsaponification matter
Flash Point
argemone oil - negative
anti toxidant TBHQ
lead ( Pb )
To use fat and oils following parameters are to be checked it varies from product to product and countries to countries .
moisture percentage
peroxide value
butryo refractometer reading or refractive index
Iodine value
saponification value
oelic acid
unsaponification matter
Flash Point
argemone oil - negative
anti toxidant TBHQ
lead ( Pb )
New Standard Pack Size To Be Introduced Soon
Indian Fmcg would have to implement standard pack sizes which were offloaded since 2004 where fmcg manufacturers were allowed to have non standard weights such as 18 g , 36g , 89g etc. which has made consumers confused while relating and calculating the price comparisons with quantity of different brands .
Maximum impact would be on confectionery , soaps , coffee and edible oil manufacturers companies which would have impact would be Britannia ,Parle , ITC , Hindustan lever , Nestle and Cadburys .
Manufacturers have to exhaust inventories of existing packing and change over to new weights , which may lead to price increase in most of the skus and product availability in market .Packaging cost would hit the profit margins as well it might also results in lowering of demand for few products . Reduction of grammage has been major cost reduction drive for many fmcgs , keeping margins thru lower weights at same price without any hike in the price .
Finally its the consumer which would gain from rationalization of packet weights giving them a clear picture of price comparison vis-a-vis weight .
The law states that the packet weight which are below 100g to label their products in terms of 25g, 50g,75g,100g above 100g to 300g it would be 100g, 150g,200g ,250g and above it would be in multiples of 100g such as 200g ,300g,400g etc . Ministry of Consumer affairs has shortlisted 19 categories of product to start with new norms applicable from 1st , July 2012 .Earlier law enacted was under standards of weights and measure ( Packaged Commodities) Rule , 1977.
here are the new standard weights norms under Indian Legal Metrology Packaged Commodities Rules
Product category New weight as per proposed amendments
source : Legal Metrology Packaged Commodities Rule .
latest news on standard pack rule
http://bakerybazar.blogspot.in/2012/06/standard-pack-size-rules-postponed-till.html
Maximum impact would be on confectionery , soaps , coffee and edible oil manufacturers companies which would have impact would be Britannia ,Parle , ITC , Hindustan lever , Nestle and Cadburys .
Manufacturers have to exhaust inventories of existing packing and change over to new weights , which may lead to price increase in most of the skus and product availability in market .Packaging cost would hit the profit margins as well it might also results in lowering of demand for few products . Reduction of grammage has been major cost reduction drive for many fmcgs , keeping margins thru lower weights at same price without any hike in the price .
Finally its the consumer which would gain from rationalization of packet weights giving them a clear picture of price comparison vis-a-vis weight .
The law states that the packet weight which are below 100g to label their products in terms of 25g, 50g,75g,100g above 100g to 300g it would be 100g, 150g,200g ,250g and above it would be in multiples of 100g such as 200g ,300g,400g etc . Ministry of Consumer affairs has shortlisted 19 categories of product to start with new norms applicable from 1st , July 2012 .Earlier law enacted was under standards of weights and measure ( Packaged Commodities) Rule , 1977.
here are the new standard weights norms under Indian Legal Metrology Packaged Commodities Rules
Product category New weight as per proposed amendments
Baby food | 100g,200g,300g,400g,500g,600,g, 700 g,800 g, 900g,1 kg, 2 kg, 5 kg and 10 kg |
Weaning food | 100g,200g,300g,400g,500g,600,g, 700 g,800 g, 900g,1 kg, 2 kg, 5 kg and 10 kg |
Biscuits | 25g, 50g, 75g, 100g, 150g, 200g, 250g, 300g and thereafter in multiples of 100g up to 1 kg |
Bread including brown bread but excluding bun. | 100g and thereafter in of multiples 100g |
Un-canned packages of butter and margarine | 25 g, 50 g, 100 g, 200 g, 500 g, 1 kg, 2 kg, 5 kg, and thereafter in multiples of 5 kg |
Cereals and Pulses | 100g, 200g, 500g, 1 kg, 2 kg, 5 kg and thereafter multiples of 5 kg |
Coffee | 25g, 50g, 100g, 200g, 250g, 500g, 1kg and thereafter in multiples of 1kg |
Tea | 25g, 50g, 100g, 125g 250g, 500g, 1kg and thereafter in multiples of 1kg |
Edible Oils Vanaspati, ghee, butter oil | 50 g, 100 g, 200 g, 500 g, 1 kg, 2 kg, 3 kg, 5 kg and thereafter in multiples of 5 kg |
Milk Powder | Below 50g no restriction, 50 g, 100g, 200g, 500 g, 1 kg and thereafter in multiples of 500 g |
Non-soapy detergents (powder) | Below 50 g no restriction, 50g, 100g, 200g, 500g, 700g, 1kg, 1.5 kg, 2 kg and thereafter, in multiples of 1 kg. |
Rice(powdered), flour, atta, rawa and suji | 100g, 200g, 500g, 1kg, 2kg, 5 kg and thereafter in multiples of 5 kg. |
Salt | Below 50g in multiples of 10g, 50g, 100g, 200g, 500g, 750g, 1 kg, 2 kg, 5 kg and thereafter in multiples of 5 kg |
Soaps | 25g, 50g, 75g, 100g, 125g, 150g, the multiples of 50g |
Aerated soft drinks, non-alcoholic beverages | 65 ml (fruit based drinks only), 100 ml, 125ml(fruit based drinks only), 150 ml, 200 ml, 250 ml, 300 ml, 330ml(in cans only), 500 ml, 750 ml, 1 litre, 1.5 litre, 2 litre, 3 litre, 4 litre and 5 litre |
Mineral water and drinking water | 100 ml, 130 ml, 150 ml, 200 ml, 250 ml, 300 ml, 330 ml, 500 ml, 600 ml 750 ml, 1 litre, 1.2 litre, 1.5 litre, 2 litre, 3 litre, 4 litre and 5 litre |
source : Legal Metrology Packaged Commodities Rule .
latest news on standard pack rule
http://bakerybazar.blogspot.in/2012/06/standard-pack-size-rules-postponed-till.html
Happy Happy From Parle
Parle has recently launched a new chocochip cookie named - Happy Happy to cater for lower segment of premium biscuit which could be bought by common man with price tag of Rs 5/- . Premium segment of chocochip variant is catered by its Hide -seek and Milano brands.Competition comes from Britannia s Tiger & Choconut varieties .
Britannia's " Good Day " Completes 25 years
Britannia 's power brand Good day completes its 25 years of existence launched in 1986 and is worth more than Rs 100 crore brand rightly placed as one of the power brand from Britannia .which includes Marie , Milk bikkis, Bourbon , Fifty - Fifty , Nutri choice
Its origin can be attributed to the Britannia R & D which bridged the gap of biscuit and cookies . Good Day is the major product as far as market leaders from Britannia is concerned . Good Day biscuits could not be replicated by competitors like Parle , ITC and now United Biscuits . Of course Unibic has come closer by creating a cookies niche in biscuit segment successfully .
Rich in recipe the Good Day has been popular among masses with its bite and taste . In addition Britannia has used ingredients like cashew , pistacchio and chocolate to add spice to it brand .
Good Day biscuit has now many variants such as Butter , Cashew , Pista ,Chocochips, Choconuts . Britannia has planned to showcase Good Day with human touch in its tvc and media campaign .
Good Day complete 25 years |
Rich in recipe the Good Day has been popular among masses with its bite and taste . In addition Britannia has used ingredients like cashew , pistacchio and chocolate to add spice to it brand .
Good Day biscuit has now many variants such as Butter , Cashew , Pista ,Chocochips, Choconuts . Britannia has planned to showcase Good Day with human touch in its tvc and media campaign .
Industrial Sewing Machine For Conveyors
Most of Indian biscuit manufacturer use cotton conveyors for their conveyor requirements and with time these cotton conveyors get worn out and start tearing apart at various places , thus conveyor web related break down are very high in such biscuit unit. Stitching of web is time consuming if done manually .
Solution to these problem have been tackled by following steps .
Preventive maintenance method where by a dedicated web inspection team is formed to monitor the health of conveyors and immediate action is taken to prevent further damage
Replacement done irrespective of cotton web condition after deciding the life of conveyor .ie 12 months, 18 months etc.
To reduce the time taken to repair the damaged cotton web , industrial sewing machines are now being introduced to stitch the worn out cotton conveyors as manual stitching takes more time . Industrial sewing machines are motorised and need a platform to perform the operations in less time . The quality of job obtained from these machines is good in comparison to manual stitching as the threads generally do not come out in case of job done through industrial sewing machine.
One of the most popular industrial sewing machine which have found application in biscuit industry is "JUKI" sewing machines , it has wide range of industrial sewing machine to cater various application in biscuit industry .
Solution to these problem have been tackled by following steps .
Preventive maintenance method where by a dedicated web inspection team is formed to monitor the health of conveyors and immediate action is taken to prevent further damage
Replacement done irrespective of cotton web condition after deciding the life of conveyor .ie 12 months, 18 months etc.
To reduce the time taken to repair the damaged cotton web , industrial sewing machines are now being introduced to stitch the worn out cotton conveyors as manual stitching takes more time . Industrial sewing machines are motorised and need a platform to perform the operations in less time . The quality of job obtained from these machines is good in comparison to manual stitching as the threads generally do not come out in case of job done through industrial sewing machine.
One of the most popular industrial sewing machine which have found application in biscuit industry is "JUKI" sewing machines , it has wide range of industrial sewing machine to cater various application in biscuit industry .
Parameters For Bakery Ingredients - Flour
In series of parameters used for major ingredients in bakery industry . we would explore parameters for flour .
Moisture
Total Ash
Acid Insoluble
Wheat germ oil acidity
Alcoholic acidity
Gluten %
Water absorption % ( WAP)
Sedimentation value ( SV )
Ageging ( Millers end )
Maltose Value
Granularity
Falling No
Alfa toxins
Heavy Metals
Each parameter is important with different values or standards for different bakery products . Hence a professional baker or bakery needs to evaluate flour quality with above mentioned parameters .
Moisture
Total Ash
Acid Insoluble
Wheat germ oil acidity
Alcoholic acidity
Gluten %
Water absorption % ( WAP)
Sedimentation value ( SV )
Ageging ( Millers end )
Maltose Value
Granularity
Falling No
Alfa toxins
Heavy Metals
Each parameter is important with different values or standards for different bakery products . Hence a professional baker or bakery needs to evaluate flour quality with above mentioned parameters .
Bisk Farm Comes Up with RUSKIT
courtesy-biskfarm.com |
Biskfarm a regional power brand in biscuit segment especially in eastern sector of India. Rusk is pre dominatly liked by elderly people and workers for source of break fast alternative and people have liking of dunking bread into tea. It would be interesting to see how Bisk farm captures customers preference in rusk . Variant which are popular are butter rusk , sooji rusk and milk rusk .
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