Bauli Croissant In Delhi

Popularity  of  Bakery products   could  be gauged  by the  variety and types of  products now available in shelf in Indian super markets  and hyper markets . One  such  example  is  availability  of  Italian major brand  Bauli   .  Croissants  with  cocoa  cream  packed in attractive packs .

Cracker Biscuit From Britannia

Crackers  are popular segment in salty  biscuits world  wide   loved by  people  who prefers low sugar  and low fat  snacks . Britannia brings these crackers under  Nutri choice  brand .

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

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.

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

Daily Production Report In Bakery

Daily Bakery Production Report: Key Elements Every Bakery Must Track for Efficient Operations

If you are responsible for managing bakery operations, one document becomes non-negotiable on your desk every single day—the Daily Bakery Production Report. This report is the first snapshot of how the plant performed in the last 24 hours and acts as the foundation for operational decisions, efficiency improvements, and production planning.

In modern bakeries, especially medium and large units, ERP systems such as SAP and Oracle automatically capture and present this information in real time. However, many small and conventional bakeries still rely on Excel-based reports prepared by production executives or supervisors. Regardless of the format, the importance of a well-structured daily production report remains the same.

A properly designed bakery production report provides a complete picture of production, resource utilization, quality performance, and operational losses. This article explains the critical elements that make a daily bakery production report truly effective.

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Why a Daily Bakery Production Report Is Critical

A bakery production environment is fast-paced and highly sensitive to variations in raw materials, manpower, utilities, and machine performance. Without a daily report, deviations remain hidden until they turn into losses.

A daily production report helps to:

• Monitor actual production versus plan

• Identify wastage and inefficiencies early

• Track labour and energy usage

• Review quality performance

• Support daily review meetings

• Enable corrective actions for future shifts

In short, it converts data into actionable insights.

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1. Production Output

The most important section of the report is actual production achieved.

Production should be reported in appropriate units depending on product type:

• Loaves or numbers

• Cartons / CBBS

• Kilograms

• Tonnes

This data helps management compare planned production vs achieved production and immediately identify shortfalls or overachievement.

Clear product-wise and line-wise production reporting is essential for bakeries with multiple SKUs.

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2. Number of Mixings

The number of mixings is a critical control parameter in bakeries.

Tracking mixings helps:

• Verify adherence to production plans

• Monitor dough preparation efficiency

• Identify under- or over-utilization of mixers

Mismatch between mixings and output often highlights issues such as incorrect batch sizes, excessive rework, or operational inefficiencies.

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3. Labour Deployment and Efficiency

Labour is one of the largest cost components in bakery operations. The daily production report should clearly capture:

• Number of workers deployed

• Total labour hours

• Overtime hours

• Labour efficiency or productivity

Labour efficiency can be expressed as:

• Output per labour hour

• Labour hours per unit of production

Tracking labour data daily allows management to:

• Control overtime

• Optimize shift planning

• Improve workforce productivity

• Identify skill or training gaps

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4. Fuel Consumption

Fuel is a major contributor to bakery operating costs, especially where ovens run continuously.

Fuel consumption should be reported as:

• Litres per day

• Fuel consumption per unit of production

This data helps in:

• Monitoring oven efficiency

• Detecting leaks or abnormal consumption

• Benchmarking energy usage

Sudden spikes in fuel consumption often indicate maintenance or process issues that require immediate attention.

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5. Electricity Consumption

Electricity usage should be tracked in kilowatt-hours (kWh).

Key metrics include:

• Total electricity units consumed

• Electricity consumption per unit of production

Daily monitoring helps bakeries:

• Control energy costs

• Identify inefficient equipment

• Support sustainability initiatives

• Improve overall energy efficiency

ERP systems simplify this by integrating meter readings directly into reports.

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6. Defective Production and Wastage

No bakery operates without some level of wastage, but uncontrolled wastage erodes profitability.

The report should include:

• Quantity of defective products

• Percentage of wastage

• Reasons for wastage (if possible)

Regular tracking helps:

• Identify recurring problems

• Improve process control

• Reduce raw material losses

• Strengthen quality discipline

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7. Dispatch or Sales Data

Production is meaningful only when products are dispatched or sold.

The daily report should include:

• Quantity dispatched

• Product-wise dispatch details

• Pending orders or backlog

This ensures alignment between:

• Production

• Sales

• Inventory planning

It also helps avoid overproduction or stock pile-up.

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8. Dividing Weights

Dividing weight is a critical quality and compliance parameter, especially for regulated markets.

Daily reporting of dividing weights ensures:

• Correct portioning

• Consistent loaf or biscuit size

• Compliance with declared net weights

Deviations here can lead to quality complaints and regulatory non-compliance.

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9. Packet Weights

Finished product packet weights must be monitored daily to ensure:

• Compliance with label claims

• Consumer trust

• Reduced giveaway losses

Reporting packet weights helps balance between underweight risks and overfilling losses.

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10. Quality Index Score

Many organized bakeries track a Quality Index Score, which may include:

• Product appearance

• Texture and taste

• Packaging quality

• Customer complaints

Including a quality score in the daily report ensures that output quantity never overshadows product quality.

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11. Raw Material Stock (Opening and Closing)

The report must capture:

• Opening stock

• Closing stock

• Key raw materials such as flour, sugar, fat, yeast

This supports:

• Inventory control

• Production planning

• Loss prevention

Accurate stock data also helps reconcile consumption with production output.

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12. Finished Goods Stock

Finished goods inventory should be tracked daily to:

• Avoid excess stock

• Maintain freshness

• Align production with demand

This data helps sales and dispatch teams plan efficiently.

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13. Available Production Hours

The report should include:

• Total available machine hours

• Planned production hours

• Actual running hours

This forms the basis for capacity utilization analysis.

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14. Breakdowns Percentage

Equipment breakdowns directly impact productivity.

The report should record:

• Duration of breakdowns

• Percentage downtime

Tracking breakdown data helps:

• Improve preventive maintenance

• Reduce unplanned stoppages

• Increase equipment reliability

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15. Gaps in Production

Production gaps should be reported in hours, highlighting:

• Idle time

• Waiting periods

• Process interruptions

Understanding gaps helps optimize scheduling and eliminate bottlenecks.

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Role of ERP Software in Bakery Production Reporting

Modern bakery ERP systems like SAP and Oracle make production reporting effortless by:

• Collecting data automatically

• Providing real-time dashboards

• Enabling instant analysis with a single click

For smaller bakeries, Excel-based reporting still works, provided the format is structured and data is reviewed daily.

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Conclusion

A daily bakery production report is far more than a routine document—it is a powerful management tool. When designed correctly, it provides a complete operational snapshot, highlights deviations, and supports informed decision-making.

Whether generated through advanced ERP systems or simple Excel sheets, a comprehensive daily production report helps bakeries:

• Improve efficiency

• Control costs

• Maintain quality

• Achieve production targets consistently

In an increasingly competitive bakery industry, data-driven operations are no longer optional—they are essential for sustainable growth.

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

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 .

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

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 .

'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 .

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 )

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 

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