FRENVI PVT LTD - New Start Up Company Into Biscuit Manufacturing

 Frenvi  Pvt  Ltd  is  an   Indo -German  enterprise  , which is into  environmental friendly food processing   business  .  They have developed  and are manufacturing  compostable and eatable spoons  for   restaurants , hotels and food stall in various countries.  

It has now  entered  Indian Biscuit  industry  to manufacture   wide variety  of  biscuits . Manufacturing Unit  is based  at   Harohalli , Bangaluru , Karnataka .  Plant  is  equipped with  all modern machineries  to  manufacture biscuits  and do the packaging .   They  are  also  FSSC 22000,HACCP,FSMS  compliant  and adhere to  all International quality  standards . Storage  space  is  large enough to cater  big orders.

Frenvi  has  experienced food professional to  develop and produce  all kind of  biscuits  . Now  they are  eager  to enter  Indian  biscuit  sector .. Following are  highlights  for  FRENVI Biscuit  divison .

1.  Can do private label  Manufacturing 

2.  Contract Manufacturing  

3.  New Product development  which includes  recipies 

4.  Do  trial  run   for   new products

5.  New packaging  ideas 

6.  Production upto 12.0 tons/ day .  Thus  can cater  for  small orders 

Contact for your  private label  and contract manufacturing  enquiries  

Email :info-india@frenvi.in

Website:wwww.frenvi.in  / www.frenvi.de

Mobile Number : 09035804172

Purchase Role In Bakery Operations

Purchasing role in any  organization is considered to be  important as  it handles raw material which in turns have significant cost  impact on material manufactured . Purchasing is key element of  supply chain management of  any bakery   more ever in  recent times as sourcing are done  from many countries .Bakeries  with robust purchasing department  and experts  give better results than others .

 Every bakery entity has got a procurement department or a executive who handles all purchases depending upon the size of the bakery unit  .Big bakeries  have multilocational purchase  unit or in some case purchases are made from central unit .

 Purchase department primary role is to  get  right material at right cost , from right buyer , of right quality and in right time .

 Major role of purchase are following for  any bakery operations 

 

• Raw Material , Ingredients ,  packaging material & fuel  buying
• Service  contract
• Vendor  Development
• Vendor Analysis
• Value Analysis
• Annual  Contract ( Plant  and machinery )
• Capital Purchases .
• Maintenance and Repair contracts
• Payments  to vendor .
• Inventory control
• Negotiations & long term contracts
• Scrap management -  Laminates , dough , carton , metals  from plan and equipment , oil and ingredients
• Getting licenses for  storages etc.ie liasioning with govt depts
• Imports
• Maintaining and Updating Vendor Master.
• Follow up  with  vendors for Delivery
• Warehousing/Stores
• Imports
• Services contract ( Others  excluding   plant and machinery )
• Legal and laws of contract
• Purchase Orders and Other Documents ( Quotation , PO , Indents)
• ERP -Data Analysis
•  

Purchase department in bakery are  responsible  for selecting the best offer  considering various aspects such as vendors capacity ,quality , delivery ( purchase order requisition) followed by purchase dept  inviting quotation from suppliers  and selecting the best offer considering various aspects such as vendors capacity , quality , delivery schedule ,price and other factors .Purchase orders are released against requisitions . Material is delivered on specified date and location by the vendors.

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Top 10 Data To Monitor Bakery Production Performance

                                              Chart - Illustration purpose only

Every bakery plant owner or  plant head needs to monitor these top 10 figures to  monitor production performance  of the  plant . Few companies depute independent factory cost control department with main objectives to  tabulate these figures to management and  to   target improvement . If you can measures things then you can improve  performance .

1 .Cost per unit ($/unit) -

Takes into  consideration  cost  of all factors such as labour ,fuel, electricity , raw material , packaging and  other miscl cost 

2.Man-hours/unit 

Number of labour employed per unit of  product normally in tonnes or kg  of product. Important cost factor in production cost of any  factory 

3. Units produced/unit time 

total production done in unit time could be in kg/hr or tonnes/hr 

4. Break down time (%)

Production stoppages due to machine or equipment failure against available running hours . 

5.Change over time ( min/hrs )

 Time  taken for  changeover of product from one sku to another.  It requires change of  moulders/cutters, recipes  and  packing  machine  settings. Changeover  should be minimum as this  results in loss  of  energy ,power and  idle  labour.The  best option is  to have dedicated lines  with least changeovers

 

6.Waste (%)   

Process  generates  waste  in  bakery operations  and can  be  categorized as waste in  mixing/premixing/forming /baking/packing /transportation

7. Defectives (%)  

Defective are  generated on equipment's   such  as  oven and  packing  machines.  Could be wet defectives or dry defectives  need to be segregated and measured before  recycling or discarding it in waste . Better to keep logs of defective at each equipment  to monitor the largest source of defective generation 

 8.Fuel consumption ( litres of hsd/gas /unit) 

Consumption of fuel  to produce unit of product basically fuels consumed  in  ovens/ and  power generation

9.Electricity consumption (kwh/unit) 

It measures the  amount of electricity consumed while producing  bakery products  . It includes power to run production machinery , utilities and admin block power consumptions . Thus  few loads are  variable but few are constant such as Utilities ( Compressors , Etp , Cold rooms, Chillers , Borewell. Lighting   etc   and admin  )

10. Inventory turnover ( %)

Its measure the cost of goods sold over average cost of inventory held . A low inventory turnover can show that company  has  low sales  hence large inventory where as higher value of  Inventory turnover  njumber  would suggest  faster sales  and low inventory of finished good .

Normally   most of the  bakery  companies  have    daily / weekly / monthly  review  of these figures

( data )  and steps  to  increase productivity and lower cost of production .

 

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Inventory Cost Control In Large to Medium Bakeries

Large to medium bakeries  needs to have inventory  cost  control system in place

What  are  inventory cost 

INVENTORY  PROCUREMENT  COST

• Cost of order processing  from the  purchase indents  stage to accounts  and finally  to the delivery of item to the factory . Cost involves  the stationary , employee and the time spent on
  these activities.

• Cost of transmission of orders  from purchase deptt  to suppliers , fax , telephones  cost of
  postages etc  with advent of internet  and erp  there has been considerable drop in these costs .

• Cost  of  transportation  including freight , octroi , transit insurance  and protective packaging for the same

• Cost of invoice ,book entries  and processing payments

• Cost of  Inspection , handling , receiving

INVENTORY CARRYING  COST

• Space  rent  for the storage  of goods

• Cost of  Working Capital locked in the inventory

• Cost of insurance of goods

• Cost of spoilage of goods  in storage , breakages in handling

• Cost  of  deterioration  and obsolescence of  goods due to passes of time

• Cost of space utilized during the storage of the product

We don't give much of importance to inventory lying in our stores or warehouse . Its when

some consultants points out that we have blocked money in these stocks that we realize that something has to be done to cut cost of inventory . . Its important to monitor inventory of RM/PM/Engg spares and even Finished goods ( FG ) , If not done it can severely impact the bottom line of business . These steps are applicable for  all items used in bakeries which have considerable cost impact 

Inventory  are maintained for following items in large to medium  bakeries

a )  Raw material and ingredients

b) Packing material and consumables

c) Engineering / Plant  Machine spares and consumables 

d) General office and utilities spares  and consumables 

e)  Finished Goods

Reasons why  stores have large inventory  are 

1  Change  in  recipe  

2. Change in packaging due  to several reason such as marketing . price or legal compliance

3.  Rejection  at   any stage in process  after inspection 

4  Slump  in sales  

5. Wrong  specification s  given at  the time of order placement 

6  Due  to  supplies  constrains  one has  to  keep  inventory   of certain critical items 

7 Duplicate Indents 

Inventory  Cost Control  techniques 

 1. Codify all items which are kept as stock in stores or warehouse .Use any inventory management software to track stocks and movement from one center to another. 

2.  Install  ERP software such as  BAAN or SAP   for better control on inventory  if you are  large to medium unit 

3. Classify items by ABC so you know what are high value items and keep a tab on their consumption and procurement . Next focus on low value items .

 4. Examine value of items on basis of return on investment .

 5.Identify high stock out items and then adjust buffer stock on cost trade off basis 

6.Examine all items for safety stocks with respect of lead time , demand , stock out cost , carrying , ordering don't pile up stock intuitively 

6. Do physical stock verification periodically and eliminate dead stocks ,accept obsolescence write off for these items . 

7. Determine Economic Order Quantities of all items .thus eliminating chances of excess material  lying in store blocking capital 

8. Shift owner ship  of  storage to vendors /suppliers  with  Annual contracts /Replenishment contract with  fixed quantity order or as and when requirement .

Thus  plant management needs  to  audit and review  stores and warehouses in regular interval to check  inventory levels  of  goods lying in stores .

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Major National Organisation , Boards Linked To Food Processing

GOVT ORGANISATIONS

Here is the list of major organizations which helps government in policy making , monitoring ,research  and  promote  food industry 

 INTERNATIONAL 

• Food And Agriculture  Organization(FAO) http://www.fao.org
•  International Organization for Standardization(ISO) http://www.iso.ch 
• International Plant Protection Convention http://www.ippc.int/cds_ippc/IPP/En/default.htm Office International des Epizooties (OIE) http://www.oie.int
• World Health Organization(WHO) http://www.who.org 
• World Trade Organization(WTO) http://www.wto.org 

 NATIONAL 

• Ministry of Agriculture 
•  Department of Agricultural Research and Education http://dare.nic.in
•  Indian Council of Agricultural Research http://www.icar.org.in 
•  Department of Agriculture and Cooperation http://www.agri.coop.nic.in
•  Directorate of Marketing and Inspection (DMI) http://agmarknet.nic.in 
•  Directorate of Plant Protection Quarantine and Storage 
• Central Insecticides Board and Registration Committee http://cibrc.nic.in 
•  Department of Animal Husbandry and Dairying http://www.nic.in/dahd/
•  Integrated Fisheries Project http://ifpkochi.nic.in 
•  Department of Atomic Energy http://www.dae.gov.in Bhabha Atomic Research Centre http://www.barc.ernet.in 
•  Ministry of Commerce and Industry http://www.commin.nic.in
•  Department of Commerce http://commin.nic.in/doc Agriculture and Processed Food Products Export Development Authority (APEDA) http://www.apeda.com 
•  APEDA has registered with Food Products Exporters for certain food products  http://www.apeda.com/ecom/scripts/exp_dir_entry.asp 
•  Cashew Export Promotion Council http://www.cashewindia.org
•  Coffee Board http://www.indiacoffee.org 
•  Directorate General of Foreign Trade http://dgft.delhi.nic.in
•  Export Inspection Council (EIC) http://www.eicindia.org Export Inspection Council (EIC) registers exporters for exports of Commodities for which certification is compulsory.
•  1) http://www.eicindia.org/eic/units/rice.htm
•  2) http://www.eicindia.org/eic/units/black_pepper.htm
•  3) http://www.eicindia.org/eic/units/marineproducts_1.htm 
• 4) http://www.eicindia.org/eic/units/milk.htm 
• 5) http://www.eicindia.org/eic/units/egg.htm
•  Marine Produce Export Development Authority http://www.mpeda.com 
•  Spices Board http://www.indianspices.com 
•  Tea Board http://tea.nic.in http://www.teaindia.org
•  Ministry of Consumer Affairs, Food and Public Distribution http://www.fcamin. nic.in
•  Department of Food and Public Distribution http://www.fcamin.nic.in/civil_ind. html 
• Directorate of Sugar http://www.fcamin.nic.in/sugar_ind.htm
•  Directorate of Vanaspati, Vegetable Oils and Fats http://www.fcamin.nic. in/sugar_ind.htm 
•  Department of Consumer Affairs http://www.fcamin.nic.in/cons_ind.htm 
•  Bureau of Indian Standards http://www.bis.org.in 
•  Ministry of Defence http://mod.nic.in
•  Defence Food Research Laboratory (DFRL) http://www.drdo.com/labs/dls 
• Ministry of Environment and Forests http://envfor.nic.in 
•  Ministry of Food Processing Industries http://www.mofpi.nic.in/ Ministry of Food Processing Industries regulates FPO. The list of Licences under FPO. http://www.mofpi.nic.in/venturesetup/licensing/licensing.htm
•  Prevention of Food Adulteration Act http://mohfw.nic.in/pfaact.pdf
•  http://wcd.nic.in Ministry of Science and Technology http://www.mst.nic.in
•  Department of Biotechnology http://www.dbtindia.org 
• Research Institutions Bhabha Atomic Research Centre http://www.barc.ernet.in 
•  Central Food Technological Research Institute (CFTRI) http://www.cftri.com 
•  Defence Food Research Laboratory (DFRL) http://www.drdo.com/labs/dls/dfrl/index.shtml 
•  Industrial Toxicology Research Centre (ITRC) http://www.itrcindia.org 
•  Indian Council for Medical Research (ICMR) http://www.icmr.nic.in
•  National Institute of Nutrition (NIN) http://icmr.nic.in/000229/nin.htm 
•  National Dairy Research Institute http://www.ndri.nic.in Industry 
• Associations Confederation of Indian Industry (CII) http://www.ciionline.org 
•  All India Food Processors' Association (AIFPA) http://www.aifpa.com 
•  Confederation of Indian Food Trade and Industry (CIFTI) http://www.cifti.com
•  Consumers Organizations (Members of NCC) 
• Consumer Education and Research Centre (CERC) http://www.indiatrade. com/cerc Voluntary Organization in Interest of Consumer Education (VOICE) http://www.consumer-voice.org Consumer Unity and Trust Society (CUTS) http://www.cuts.india.org
• Niftem  http://iifpt.edu.in

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Kuppies Cake From Dr. Oetker

 

Dr . Oetker is  one of the  world leading food manufacturer  with products like  wine , cakes , dessert and pizza  and is present in 50 countries world wide ,

Established in 1891 Dr.Oetker  is German based food  manufacturing giant . It established Indian operation in  year 2007 by taking over Fun Foods Pvt Ltd. Fun Foods has since become market leader in  Mayonnaise, Sauces ,Spreads , Cake mixes , Dessert Toppings  and waffles . It has 

Now  very well established in Indian food market  with products  like 

Mayonnaise

Pizza and  Pasta Sauces

Cakes and waffles 

Peanut Butter 

 Entered  bakery market  with their  brownies cake   in cups  and sliced bars . Major competitor  for Dr.Oetker  are  Britannia , Parle , Cremica , Heinz , Nestle  .

 I can fondly  remember my innings with Fun Foods Pvt Ltd where I worked as Technical Trainee in year  1992  ,looking after production and maintenance  at its  Safdar jung factory   , Delhi  factory . A small  unit with  few mixers and chillers manufacturing yogurts for  various airlines .   Fun foods pvt ltd  have been taken over by Dr.Oetker  a Germany based  food manufacturing giant .

Seasoning Cube Manufacturing

Seasoning ( spices ) in cubes are prevalent in many countries , Seasoning   have distinct advantage of  savings on preparation time  for  household ,Various packaging  options such as   cubes /bars/sachets   makes  consumer  happy  in preparation of  food. Popular in European /Asean/ African  countries .

Popular  taste  available  are

Tomatoes 

Chicken

Spices

Shrimp

Cubes  manufacturing stages  are  mentioned  below 

Pre mixing

Major  ingredients  for  seasoning  are   salt , sugar , starch , maltodextrin ,  veg spices powder , flavourss and colors . All  these items are  transferred  into   storage  silos   through pneumatic  conveying . Roots blower are used as  primary  equipment  for pneumatic  conveying . Other  ingredients are added manually into mixer .  Major  ingredient handling system manufacturer is Guerin system /Tetra Pack 

Mixing 

Mixing times vary from 30min to 45 min as per  recipe .  Horizontal mixers are widely used for large scale production .   Mixers have horizontal arms witth blades .

Maturation  

Seasoning batch  prepared  is then transferred into bucket conveyor s .These have long travelling time to  mature  seasoning  product . Maturation plays important role  for  product to be packed in cubes .  . Average  maturation time varies from 180 mins to 240 mins ,

Cube - Tablet making 

Seaoning powder after  maturation   are fed into  tablet making equipments  where   these powder  are compacted into  cubes  through  pistons . Major tablet making manufacturers are  Ramco Kilian / Bonal 

Packaging - 

High speed cube packing  machines are  used for  seasoning cube packaging . Speed varies from  800 ppm to 1000ppm . Packed into  cartons .

Popular hfw packing machines are   Theegarten-pactec. Senzani 

Cubes are then packed into cartons for  dispatches  to retailers . Other  popular  method of packing spices are  sachets/cartons  

Popular  international player into  seasoning cubes manufacturer are Nestle ,  Patisen 

Modern Bread - Into New Avatar

 

                                                Modern Bread

One could never forget the Modern bread’s lip-smacking flavours!

Right from fruity flavor till the classic salt bread, each and every one of us would have had a slice of it, either knowingly or unknowingly. Modern bread  into wax  paper  packaging with long que

Be it toasted, dunked, topped, sliced or sandwiched! We might have had one!!

History

Started as Modern Bakeries India Limited in 1965, the name was later changed to Modern Foods India Limited in 1982.

Being the first bread company to be privatized by the Government of India in 2000, it was later sold to Hindustan Unilever Ltd. (HUL). Last April, Modern was taken over by Everstone Capital, which is now recognized as Modern Foods Enterprises Private Limited.

A twist in the tale!

pic courtesy- Modern food

For almost many generations, Modern posed itself to be the most powerful food resource in the Indian bread market.

Do you know that the Blue & Orange Waxed Paper Bread pack from Modern was virtually synonymous with bread?

When people were very much obsessed with the taste and flavor of the bread, there came many competitors. The only option to sustain in the market is ‘Adapt to the wishes of the consumer’

By 2016, Hindustan Unilever Limited (HUL) handed over Modern foods India Limited to Everstone Capital, a private firm. Right now 100% of Modern share remains with Everstone Capital.

The route to success

So, what made Modern a strong competitor in the bread industry, when there is a tough competitor like Brittania?

As simple as ever!!

Modern always ensured that they add high-value elements to complement their nutritiously delicious products.

Experience the new

The word mark, the brand slogan, and the taste everything has undergone a transformation that gives contemporary essence to Modern.

The new motto, ‘Thrive, and savour life to the fullest’ helps to make smarter choices from its wide range of delicious bread and bakery products.

The #belikebread social media campaign bread that delivers an important message, ‘Bread doesn’t discriminate’.

Conclusion

It is therefore clear that the rebranded Modern Bread will certainly create a stir in the bread industry. The reason is that an average Indian urban consumer will be keen in experimenting and trying out a product that would match international standards.

Taste the classic bread with a modern twist and indulge yourself in a delightful taste palate.

Modern bread  are into whole lots of  bakery  products  right from bread , cakes , pizza base , bun , rusks  and  dosa batter .

you can visit modern bread site 
 https://www.modernfoods.co.in/products/

COVID -19- Impact On Bakeries

 

Covid -19   has  impacted   food  retail industry  including  bakeries in a major  way .Supplies were impacted  such as  Ingredients , Raw material and Packaging materials    Where in  most countries  factories and   shops  are  closed .Health experts have confirmed that coronavirus is not food borne and  it persist from several hours to days on surfaces . Thus  incurring 
extra cost on bakeries 

Workers  have moved out of bakeries  and have become jobless  , businesses have suffered due  to  loss   on account  of low sales or  closure .

Bakeries are  adopting   new strategies in post  Covid  period  with gradual  reopening  of  stores  with precautionary guidelines  such as 

1 . Majority  have   started home  deliveries 

2.  Social distancing in   cafe s  , where  customers  are asked to maintain   distance  while eating  or buying

3.  Seats and  floors are sanitized  in regular  intervals

4.  Personal hygiene  is   of utmost   critical   while  hand  sanitization has become norms 

5.  Online orders have been encouraged  

6.  Suppliers of  raw materials , Ingredients and Packing materials  have been  asked  to maintain the  same guidelines  

7.  Kitchen  or the production halls , utensils and machineries   are sanitized  on regular  intervals 

8.  Providing ingredients for people  experimenting  bakery recipe at home during lockdowns

9.  Production in shifts   to lower the  number of  workers 

10. Installation  of Hand free  sanitizers and dispensers 

Only  encouraging  signs for  bakeries  is that  being   an  essential  food  part   it has been allowed to operate longer hours. Governments and local  bodies  have allowed  bakery supplies  to have smooth operations in various countries .

Hope  these   tough times would end soon and we would have  normal   operations in 2-3 months 

Britannia's Croissant Now Available In Groceries

Britannia  Croissant

 Britannia last year had a joint venture  with  Chipita  - a  Greek company to  manufacture  croissant  in India . Long-awaited launch is over and croissant is now available in  major metros of India. 

Croissant,s  are  French bread made up of butter with cream-filled inside. It can be eaten with  jam or  coffee

The factory is installed at the Ranjangaon, Maharashtra.  Process of installation of the machine , trials have been completed and the product is commercially launched. Britannia treat croissant are now available in two variety of vanilla and chocolate flavors.

Croissants fill the gap for snacking on the go and is  liked by all from kids  to old generation . Its soft hence very popular with the older  generation. Can be a good replacement for breakfast. 

Britannia is trying to brand croissants in India which is produced by local bakeries. The market is estimated to be Rs 150 crores by industry experts. Britannia is already a major player in bakery products in India  with brands like  Good day, Marie Gold, Nutrichoice, Fifty - Fifty , Treat and dairy products thus has added croissants in its list of baked products.Britannia  is trying to  add other food categories for   growth outside bakery products .

Unibic Goes For Sugar Free Cookies

 Unibic  India's prime cookies  manufacturer  has  launched  sugar free cookies  catering large  population impacted by diabetes and  people  who are health conscious . 

Its  clear that   biscuit manufacturers have to cater  to growing demand  from consumer to prove  healthy alternatives  into  food items ,

Milano Minis

Parle premium cookies are  now re packaged in cups  and branded as mini cookies laden with choco  chips 

Overview Of Indian Bakery Industry 2018

Overview of Bakery Industry in India:

According to recent research, the bakery industry in India has an important place in the countries industrial map. Bakery products are an item of mass consumption in view of its economic price and high nutrient value. In the highly growing and changing eating habits of people, the increasing foreign influence and the rise of a female working population, bakery products have gained their popularity among people, contributing significantly to the growth trajectory of the bakery industry. After entry of Pizza and Burgers' MNCs in the country, people are changing their tastes also. Today, they are not restricted to bread, cake, and biscuits but to other bakery products also. The consumers are increasingly going for newer options with respect to bakery products.

Positive Aspects of Bakery Industry in India:

The growth rate of bakery products has been tremendous in both urban and rural areas at 14 percent per annum.

The global bakery ingredients market is growing rapidly and is anticipated to achieve significant growth over the next seven years.

Advancement in packaging and ongoing product diversification in baked food is expected to promote demand for bakery ingredient in upcoming years.

Challenges and Issues:

The volatility of raw materials and energy costs based on prices of wheat and vegetable oil that can vary as much as 40% in a single year.

Competition from customers within a consolidating supermarket industry.

In order to survive in an ever-changing marketplace, both bakery wholesalers and retailers must adapt to challenges faced by the industry.

Final Verdict:

Bakery industry in India is one of the largest sections in the processed food industry. It has undergone a major change on account of changing the perception of bakery products and evolving consumer tastes. By the perception of bakery products, consumption boost in the nation and changing consumer needs, we estimate the Indian bakery industry to reach levels of INR 483 billion in the next seven years. Rising urbanization and growth in the disposable incomes of the Indian population has proven to be a magnet for international bakery chains owing to which the sector has seen an entry of foreign bakery companies trading into India which has helped in enhancing the quality of Indian bakery products.

New Trends :

Any bakery enthusiasts   can   see   changes  in bakery products from whole grains to atta  biscuits /breads .  From desi to exotic   recipes of tart , ciabatta , muffins ,cinnabon,doughnuts   etc .

Following are  the new trends in baking industry
1) Premiumization
2) Gluten free
3) Bio degradable  packing
4) Organic ingredients
5) Gluten free
6) Sugar free
7) Fat free
8) Low salt 
9) Eggless
10)Multi grain
11) Hand Made
12) Ethnic -local 
13) Fortification 

Multinational  Players 

Many MNC  have now entered  Indian bakery  industry  to  get  some market share from entrenched Indian  brands  . Brands  like  Oreos from Kraft  ,  Mcvities  from  United Biscuits  and recently  we had  Bimbo  entering  Indian bakery market  with  acquisition  of   Harvest  Gold .

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