186 years Old History of Cadbury Brand

1824


John Cadbury, from a wealthy Quaker family, opened a grocer’s shop in Bull Street, a fashionable part of Birmingham. Goods include cocoa and drinking chocolate.

1831


Mr Cadbury moved into manufacturing, renting a small factory in Crooked Lane, Birmingham, to make cocoa and drinking chocolate.


1861

His sons, Richard and George Cadbury, aged 21 and 25, took over the business from their father, who was in poor health.

.1866


The brothers launched Cocoa Essence after George bought a revolutionary cocoa press from Dutch manufacturer van Houten.



1869


Production began at the new “factory in a garden”, four miles outside Birmingham, which was named Bournville.


1893


George Cadbury bought more land in Bournville to build a “model village” for industrial workers.



1897


Cadbury launched its first edible milk chocolate, created by adding dried milk powder to cocoa solids, cocoa butter and sugar.


1905


Cadbury Dairy Milk was launched to compete against the leading brands of Swiss milk chocolate.


1915

Milk Tray was launched, a no-frills box of chocolates for everyday eating.



1919



Cadbury merged with JS Fry & Sons so both companies could compete against Rowntree.


1921


Cadbury opened its first overseas factory in Hobart, Tasmania, followed by New Zealand in 1930.

1955

Cadbury moved into TV advertising on the launch night of commercial television on 22 September.

1969

Cadbury merged with drinks maker Schweppes.

2003

Cadbury became the world’s leading confectionery company after buying various chewing gum brands including Trident and Stride.

2008

Cadbury and Schweppes demerged, splitting its confectionery and drinks business.

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 .

Low fat and Zero Fat myth

Do you really check labels ?
Do you know the regulations ?
Does companies really meant what ever they show on labels ?

Watch this video  .

Bakery Cafes are profitable business - A survey

Bakery Cafe s have reported spectacular growth in  recent  economic slowdown .Manufacturing has been hit by the cost escalation how ever  the bakery cafes  are in expansion mode . A recent survey by  Technomic tells us all.

According to Technomic’s new study, the 2009 Technomic Top 25 Bakery Cafe Chains Restaurant Report, system-wide sales for the bakery-café industry grew 12 percent in 2008 to $4.5 billion, led by Panera Bread, Einstein Bros. Bagels and Au Bon Pain, with $2.6 billion, $393 million and $307 million respectively.




"The consumer trade-down from full-service to limited-service formats that solidified through 2008 and into 2009 allowed fast-casual bakery cafes to truly shine," said Darren Tristano, executive vice president at Technomic. "The appeal of moderately priced, high-quality menu offerings served in contemporary ambiance, as well as consumer perception of value for this format, has more than likely strengthened over the past year."



Among the trends, products, and findings included in the report:



Health and nutrition: Einstein Bros. Bagels' Lighter Fare Menus.

Expansion of breakfast offerings: Atlanta Bread Company, Corner Bakery Café, and Panera Bread.

Revamped catering programs: Au Bon Pain's Hot Lunch line.

Value equation: La Madeleine's Choose Two Menu, Einstein Bros. Bagels' Snack-Out menu, Au Bon Pain's small-bite Portions menu.

Nontraditional sites and urban locations: airports, college campuses, military bases, medical centers and hotels.

Social media: use of Facebook and Twitter to promote new and limited-time offerings.

Bakery cafe chains' units expanded by 6.6 percent to 3,107 locations.

Paradise Bakery & Cafe was the sales growth leader at 30.7 percent. Le Pain Quotidien was the leader in store count growth rate at 29.6 percent.

Source: Technomic Inc

Pakistan Biscuit and Confectionery business on verge of shut down

Pakistans Biscuit and confectionery Associations ( PB & CMA)  declared that they  intend to  close the biscuit plants rather than  to run plant or factories in losses. Pointing towards the soaring prices of raw material specially  Sugar  which has shot up to  Rs60/kg .  with in no time . Mr Maqsood Ismail  associations  chairman  said that untill and unless the government takes some drastic and emergency steps  there would be no choice for manufacturers to shut their factories rendering thousand s of worker jobless  and loss to  government of pakistan exchequre.

Source : pakwatan.com