Britannia s Little Heart - A product review

Britannia Little Hearts has been unique in two sense one was packing and second was bite size small heart shaped biscuit  coated with sugar .

"'Little Hearts was launched in 1993 and targeted the growing youth segment. A completely unique product, it was the first time biscuits were retailed in pouch packs like potato wafers. The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt. In 1997, the 'Direct Dil Se' campaign encouraged youngsters to openly express their feelings. And in 2003, two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign "Dil sabka actually sweet hai". With Little Hearts, Britannia has tasted the sweet taste of success. ""
Source : Britannia Industries Ltd

Here is a  review of  Britannia Little Hearts

Taste --  Good  with flavours like sesame or chocolate

Color - Dark brown , baking good

Bite-  Soft  bite

Packaging-  Pouch packing with metalized wrapper

Ingredients-Wheat flour ,Sugar,Edible vegetable oil ,Milk solids,Raising agent ,Salt ,Yeast  Emulsifiers .
and Improvers .

Calories- 474 kcal per 100gms

Price -  Rs 10/-  for  60 gms

Competitors ---    Yet to have any competitor  


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Bread Industry of India - A review

With changing lifestyle  , urbanisation,  increase in per capita income  and working spouse these all have  made bread a staple food in India as its in other western countries .We are now taking breads  for breakfast luncheon and dinner as well .

Number of bakeries have opened up in neighbour hood  where one can buy his daily quantum of bread .
India has few major national bread manufacturers namely Britannia and Modern ( takenover by switz group) number is very low as compared to other countries such as USA or UK. Bread Manufacturing is volume driven and low margin industry with an disadvantage of  very low shelf life of products which then requires very robust supply chain management to deliver fresh bread  to consumer  daily .

The bread market has a business volume of 1.5 million tonnes. The bread industry has a production of approximately 27 lakh tonnes.  The major factors for growth in this segment are:


Brand loyalty

Volumes

Strong distribution networks

The major challenge faced by the organized bread sector at present is low margins of profit. Hike in the prices of major raw materials like sugar, vegetable oil, milk, and wheat flour has been accounted for the industry's low margins of profit.

The per capita consumption of bread in India is only around 1.5 kg to 1.75 kg in various zones. The consumption pattern in four zones is Northern States: 27% Southern States: 32% Western States: 23% Eastern States: 18 % ( ref -AIBMA)

Few large regional players have grown up to make up for the demand.

North India
Harvest Gold ,Bonn ,Perfect ,National,Kitty

West India

Vibbs

South India

Spencer

East India
 Britannia  ,Modern
Apart from these automated major bread manufacturers several bakery chains have sprang across the city maps. These bakery chain s provide  customers with artisan breads  with origin of recipe from Italy , France and Swiss. such as  Daily Bread , Hot Bread , Cookie Man   Oven Pick  andseveral others


Bread Manufacturers  have  started offering consumers with varieties of bread  such as  white bread ( most popular )  brown bread ,flavoured breads( garlic ) , gluten free bread ,buns 



more on bread industry  - A report


Note : Please add bread brands from your area .

Start & Run a Home-Based Food Business

Indian Universities and Colleges offering Courses in Food Technology

With Food Industry finally gearing up in India with Govt of India declaring food processing as Sunrise Industry and numerous foriegn companies eager to enter Indian market,  opportunities for food technologist are increasing  with these developments

Here are few Major  Indian Universities which  are offering Food technology courses from Bachelors degree to Maters degree .

• BTech (food technology) HBTI, Kanpur

•  BSc (food technology), University of Delhi

•  BSc (food and nutrition) Dr Babasabeb Ambedkar Marathawada University, Aurangabad

• BSc (food and nutrition) Kakatiya University, Warangal

• MSc Tech (food tech and fermentation tech) University of Bombay

• MSc (food science), Andhra University, Visakhapatnam

• MSc (food and nutrition), University of Mysore

• MSc (food technology)  GB Pant University of Agriculture Technology, Pant Nagar.

Most these universities  takes students through entrance exams  after  completion of 12 th exams with subjects like physic , chemistry ,maths

UK Major Bakery Chain’s n Cafe

Here  are Britain’s major bakery retailers which offers baked goods as their prime products along with other products

Name	sales GBP	no of cafe
Greggs ( Bakers Oven )	628.2	1409
Subway ( Franchise)		1284
Costa ( Franchise)	263	849
Starbucks	373.5	699
SSP UK	-	445
Cafe Nero	150	385
BP –Wild Bean Cafe	-	247
M&S  Cafe	-	225
Pret  A  Manager	224	194

Source :  http://www.bakeryinfo.co.uk/

Most Popular brand of Cadburys Chocolate

Dairy Milk


Introduced in 1905, in an attempt to take on Swiss chocolate makers in the field of milk chocolate via the cunning means of putting even more milk in, Dairy Milk gradually took over the British chocolate market, expanded around the world, and boosted the mass appeal of chocolate. Or, if you're a dark chocolate snob, destroyed forever the idea of what proper chocolate should be in the public mind.


Easter Eggs

Cadbury didn't invent the idea of chocolate Easter eggs - that originated in France and Germany in the early 19th Century - but they were among the first to make them using modern manufacturing processes, first launching them in 1875, and establishing the chocolate Easter egg as a tradition.



Creme Eggs

The now-ubiquitous sugar-goop-filled ovoids didn't launch in their original form until 1971, although Cadbury had been making various forms of crème-filled egg things since 1923. They're now the biggest-selling confectionary item in the UK during the first few months of the year - we munch and slobber our way through 200 million of them every year.


Roses

Launched in 1938, Cadbury's miniature chocolate selection box is another classic brand - although in this case, Cadbury didn't get to the idea first. Roses' arch-rival in the miniature chocolate box market, Quality Street, was launched by Halifax-based sweetmakers Mackintosh's two years earlier in 1936. And, speaking for ourselves, we still reckon Quality Street's better.


Fingers

Dating all the way back to 1897, Cadbury Fingers remain as popular as ever. Biscuit. Chocolate coating. Simple. Effective.



Wispa

Discontinued in 2003, the bubbly Wispa bar was revived in 2008 following an entirely authentic grassroots campaign - including Facebook groups.


Flake

Created almost by accident - a Cadbury employee noticed how excess chocolate spilling over from the moulds fell in thin streams, creating the classic folded flake form - the Flake, launched in 1920, saw its sales soar after it introduced the novel idea of advertising it with a naked lady performing an erotic pantomime with the bar in an overflowing bath.



Fudge

A fairly basic bar, sure, consisting of a slab of fudge coated in chocolate. But the old advertising jingle - 'a finger of fudge is just enough to give your kids a treat', set to the tune of old English folk song and numbers station favourite 'The Lincolnshire Poacher' - is a maddening earworm.



Milk Tray

A box of chocolates - every ninja-like secret agent's favourite mysterious seduction technique.


Curly Wurly

The Curly Wurly's snaking strands of chocolate coated caramel are much loved, notably for the sheer joy that can be produced by getting Glaswegians to say the name out loud.



Source: http://www.metro.co.uk/

Install in motion Check Weighing machine to eliminate excess weight to the market

While going through the material  consumption variance   report one might like to know the  reasons  for it , One of the major reason in bakery product material variance s is Give aways ( over weight of packed product). Due to faulty setting s  or mechanical issues  in bread production , cake production line or biscuit production lines .
It could be due to Dividers malfunction or Cutter /Moulders setting or configuration . The major steps is to rectify the problem in the equipment first but  for detection purpose bakery plants to set up   in motion checkweighers after packing section  in biscuit manufacturing and checkweighers at dividers end to measure the weight of the dough piece .
Installation of checkweighers  would   make the conventional table top scales obsolete   at some places . These checkweighers helps bakery manufacturers in two ways
Under weight

• You can be  sure of the weights  products which comes through check   weighers  and its legal requirement for all manufacturers to adhere to the declared weight with some tolerance s.

Over weight

• Any variation of weights whether Under weights or Over weights  does harm company interests . Corrections can be done  at manufacturing areas to get the proper  weight of the product

Working Principle of Checkweigher
Work on Pneumatic  applications,  pneumatic cylinders are used for retraction or  folding of conveyors  for rejection of packets. Product s are put on the conveyors which have load cells which gauge s weight and send signals to the  pneumatic cylinders  which  are activated through  .valves  compressed air  then either retracts or pushes the folding conveyor or some checkweighers have pneumatic nozzles on the conveyors surfaces which pushes the under weights and overweights through blast of compressed air   .Which drops the under weight or over weight packets . One has to check  the packing machine output to synchronize  with check  weigher .
Specification of Check weighers

Products/per minutes- packets/min
Set Weights = +/- gms
Tolerances =+/- gms
Air Pressure = kg/cm2
Major manufacturers of  checkweighers
Mettler Toledo
Ishida
Lock Inspection
Sartorius
Wright Machinery
Check weighers now days  have data storage where all details of  weights of the product can be stored and can be  retrieved analysis.
Any variation of weights whether Under weights or Over weights  does harm company interests . Corrections can be done  at manufacturing areas to get the proper  weight of the product.

Carton sealing machines in bakeries

Finished product s be it  in biscuit/cookies  manufacturing plant or slab  cake production plants  are transhipped  into retailers  from  production hall  in cartons . Cartons  or CBB are either supplied in pre- form or  formed into  cartons . Cartons  are  filled or stuffed by these packs . The popular  configuration  available for  cartons are that of 1.5 kg , 2.5 kg , 5kg or 6kg . These carton are sealed  either from top or both from top and bottom by carton sealing machines . These carton sealing machines have adhesive  tape mounted on them which are then pressed onto the flaps of  carton and  sealing is done . Cut- off  Length of tape could be adjusted through adjusting mechanism.
Different type of carton sealer s are available  in  the market
Fixed dimensions type
Top tape head type
Top and bottom sealing type
Automatic adjustment as per carton dimension type

Basic principle of carton sealing machine
Head consists of  roller which  presses  the tape on to the  carton  and after  a particular length the cutter cuts the tapes due to spring pressure

Important parts  of carton sealing machines
Mandrel hold tapes
Head
Cutter
Bottom and top pressure roller
Side rollers
Sliding Guide  to lower  or raise the support as per the rquirement

Carton sealing machine specifications

Power supply 1P 110v/220v 50Hz/60Hz 300W/470W

Sealing speed -cartons/min

Carton size -L() x W() x H()mm

Tape size -48-72mm(Kraft or BOPP tape)

Machine size -L() x W() x H()mm

Popular Brand of carton sealer in bakery manufacturing units are
Commarme
3M
ITW Signode

Bharti Walmart cashing on Atta and Jeera Biscuits

Shelves on EASY DAY retail super market are stuffed with Atta( whole wheat flour) and Jeera biscuits . Popularity of these variety are due to fact that these are considered to healthy options against other branded biscuits .

These biscuits are outsourced /private labels from local manufacturers and marketed by Bharti walmart Easy Day .

Automation in Bread Manufacturing -Post Baking

Excellent video which I came across searching for bread manufacturing automation . Countries with highly automated bread plants can adopt these Pallet making robots without any human handling which would save on labor cost and  increase productivity. Robots are being deployed in many European and American bakeries

Watch now

What is in the name?

I have been to many cosmopolitan cities  thanks to my fathers transferable job  in Indian Air force   We moved around to many cities Major ones were Mumbai , Delhi , Chandigarh and Shillong  after completion of my education I went to complete my graduation at Bhopal . Back in Delhi for job  and then to Dubai , Musqat and Abu Dhabi in connection with Job .  Since Child hood I  have been visiting Bakeries  for our Daily  breakfast breads and Cookies for snacking .  Celebrations were done with Cakes and Pastries all  from  nearby  bakery shop .
I can still remember the smell of baked goods in these small bakeries  and with unique names  such as “ Bake n Shop” ,
“City Bakers”  etc . Getting stuffs in oily paper bags .We could get our own recipes made with these bakers .
With ever expanding  popular bakery chains and cafe opening in every popular joints in city landscape we are getting new names . I have wondered  what went in to these bakery owners  mind before naming their  shops , cafe , brands .
Some were based on location  ,others on owners family name  and some on the origin of  products such as Swiss , French or Italian  each catering specific population .
Fascinated by their names  I started to collect  these names   and could be read  at
Buy Ebook On Bakery Names

Do add your favorite names .

Top Pizza manufacturers and Retailers in USA

Pizza  or Pizzaria Industry  has seen robust growth in last year in USA . Pizza is one of the few segments that crosses the entire spectrum of the restaurant industry. Pizza is  spreading from the quick-service segment to the fast casual and casual dining areas. It is even represented by gourmet and fine dining.

Few popular  sauces  offered  in USA
Tomatoes ,garlic butter , Alferdo , Barbeque , Hot and Spicy

Apart from regular cheese , roasted vegetables  non veg options are hot favorite among Pizza lovers.
Few of the popular toppings apart from vegetarian  in pizzeria industry USA
Pepperoni , Italian sauges,Chicken,Pork Saugages,Ham, Bacon,Ground Beef,Shrimp ,Anchovies and Clams


Top Pizza manufacturers , Retailers and Chains  in USA

• California Pizza Kitchen
• Cici s Pizza
• Domino Pizza
• Fox Pizza
• Little Caesars
• Papa John
• Papa Murphys
• Pizza Hut
• Pizza Inn

Few of them have presence  across the globe for example  Domino s, Pizza Hut or Papa Johns

How to get better Yields/Output in bakery manufacturing units

Yield  can be defined as finished products per unit of inputs for example  100 cartons per x kg of flour . Manufacturing units  have certain wastages which if  reduced or eliminated can enhance out put of the process . bakery processes  such as mixing , forming and baking have certain wastages which results into  wastage's .  Other  wastage's can be  considered as give aways  such as excessive weight .
Here are few process in bakery which results  into wastage's and low yield .
Pre mixing Area
Flour  and Sugar Dust wastages at  sifters  and during bulk transfer through pneumatic conveying to silos .These can be reduced and eliminated by  proper maintenance of equipments and tightening of fastener and gasket where ever possible s. Conveying pipelines have flanges which when loose can result in flour or sugar wastage .  Sweepings can show the extent of flour or sugar dust wasted .
Mixing  Area
Mixers  are the most important equipment which prepares the dough  dough leakages and spillages can be eliminated by providing proper inlets to mixers and unloading of dough in trolleys and dough trucks .
Forming Sections
Bread
Dough leakages are found at  Dividers  which can be reduce by proper maintenance . Over weight dough pieces can go to the next phase if not checked  mechanical dividers sometimes give overweight dough pieces .Flour dusting if done has to be monitored .
Biscuit
Dough leakages are found at laminators rolls , gauge rolls  and moulders  these can be reduced by providing flanges at the sides . Moulders /Cutter if not set properly can results in over weight product which results in lower yields. Weights are to be checked in regular interval  at this stage .Flour Dusting done has to be monitored regularly .
Baking
Burner Parameters ( Temperatures ) to be monitored continuously  which  if not done can result into unbaked or over baked products which has to be rejected .
Packing
Major problem in packaging are defective packing due to  labels ,sealing problem  or Under weight /Overweight rejections ( has to be rectified at forming section or baking section ) .
Packaging parameters to be monitored regularly for any packing defects as these results in  REWORK which  again reduce  the Yield .
Spillages
Most of the liquid ingredients which are  transferred through pipelines are to be checked for spillages such as Fat , Milk , Butter  etc .

How to Increase Labor Productivity in Bakeries

Increasing labor productivity in your bakery means increasing value added per worker or per hour worked.
Many bakery plants in developing world are labor intensive  .Workers  are involved in most of the jobs such as transportation , packaging , feeding to mixers and packing machines , unloading and loading at stores and dispatch , Material movement inside production hall ,Ingredient preparation  ,Hygiene and sanitation , pest  control , rework , taping , sealing and other miscellaneous activity .
Output of any manufacturing unit can be increased by automation  or  capital investment but it would require major capital investment which most of the bakeries are not in position to do .
Hence other options are smaller modifications in plant layout  to increase productivity,discovering any new recipe with lower  cost ingredients  or  optimize time of process .Options for labor productivity  are either  you control on several wastages in labor activity or Innovate in process.

Wastages which  results in  low productivity  are

Waste during Operations  -Too much handling of products and  packing material .
Waste of Movement – To much movement in packing section where movements involves
                                    .Packing material from stores to shop floor
                                     Changeover  to different product
                                     Re work of rejected packets
                                     Taping on cartons
                                     Labeling , coding , stickering  and strapping
                                     Transferring carton boxes  to pallets
Waste on Rework -  Companies are focused for  production figures rather than quality products through  process with quality checks in place.  Rejected materials are then re worked for packaging involving labor .World class measures defects in parts per millions ( PPM)  where as here in our country budgeted defects are in terms of 5%-3%.
Physical strain and stress on workers – Process have certain activity where workers are physically stressed or strained impacting productivity  . One of them is material handling   which can be reduced by having equipments such as pallets trucks , trolleys , chain hoist , drum tilters , forklifts etc.Working Environment also adds to worker productivity  companies have to provide dust proof ,proper ambience in their factory to work .Few standards are  mentioned in Factory Act which relates to  min and max weight s which a worker can handle  , noise , sanitation , height and lighting of factory .

Areas of Improvement in big and medium bakery manufacturing units

 

In coming months I  would  be putting up thoughts on improvement  topics for bakery  manufacturing units . Bakery manufacturing units  or bakery businesses  have functions like sales and marketing , procurement , finance ,stores /warehouse , quality  apart from production .

Following are areas  for improvements in big and medium scale bakery manufacturing units

• 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

Above mentioned factors are critical for any  business   and  have to be monitored  by company management for better results .