REPORT ON INDUSTRIAL VISIT SURYA FOOD AND AGRO LTD.

SUBMITTED BY- TANYA KHURANA PGP20125599

IILM Institute organized an industrial visit to Surya Food & Agro Ltd, Noida as a part of the Program for its first year batch 2012-14 on 27th July'12. The vis it was intended to expose the participants to the real industry where they would see themselves in the near future. It was organized by our placements team whic h is headed by Mr. Raghuvansh Mathur. and was made compulsory for the selected 3 0 people from each campus ie- Gurgaon and Lodhi Road. On the day, we assembled a t the campus gate at 8:00 in the morning from where Ms. Pragya Sonawane from the faculty had accompanied us for the visit. On arrival, we were welcomed by Mr. B C Dhyani (Production Manager) and Mr. S P Pandey (Production In-charge) who were responsible to take us to tour the facility and also explain the entire process of manufacturing. The Company owns three productions units across India and eac h unit has a specialized range of product to manufacture. The plant we visited at Noida was specialized for the production of biscuits like CnC, Snacks and Ma rie Lite. This plant is the largest of all plants owned by the company with a ca pacity of producing 500 tonnes of biscuits per day. The total employee strength who are engaged in the complete process is about 1500 people across India. Apar t from this they have a developed a strong distribution channel through the 100 super stockiest and 3500 distributors which are spread across the country. The complete production and packaging of the product is planned and the plant is designed in a way that there is a proper directed channel taking in line from t he starting to the end of the process. The complete making involves 5 integral stepsMixing Molding Baking Cooling Packaging MIXING This is a process where all ingredients are put together in right proportion for dough formation. Major ingredients are flour , fat ,sugar and others as per the product. These ingredient are then fed into Mixers where mixing is done and dou gh is prepared for molding. While mixing, following points needs to be considere d for better results. Mixing time : Normally any mixing can be done within 15-25 minutes and much depends on speed of mixer , flour characteristics or temperatures required for d ough. Dough Temperatures : The temperature of the dough should range between 35 deg c - 42 deg c as per variety of the biscuit. Dough consistency: This is checked manually by stretching the dough. It should n ot break and neither should it be very elastic. For cracker variety - Dough should have additional ingredient like yeast and sho uld be kept for 10- 24 hrs.

MOLDING In this section, the dough is passed through several rolls to form sheets. This sheet is then converted into one uniform sheet of desired thickness, generally 6 -5mm. Moulder/Cutter is then used to give the variety of the shape and sizes. Above process is mainly for cutting variety. It also includes dough sheet condit ioning, which is done as per the ambient conditions of the plant. Steam Spray- to moist the web surface. Blower- to dry the dough surface. Floor dusting- to dry the wet surface of the dough. Toppings- They are done through mechanical, vibratory or sprays and a hopper is placed above the plant line after the cutter. The toppings could be milk, salt, sugar, cashews, pista nuts etc.. BAKING This process involves the heating of the wet dough pieces of desired size and sh apes in the oven band. They are passed through swivel panel web. Heat is transfe rred on band through all the three ways of heat transfer ie- conduction, convect ion & radiation.Both physical and chemical changes happen in the oven band. COOLING This is the most important step in the process. When biscuit is taken out of the oven, the temperature for them is around 75-90 degree C. These biscuits are the n cooled at room temperature by passing them over the conveyor belt for distance of 1.5 times of the baking time. This makes the biscuit ready for packaging. PACKAGING These biscuits are now fed into packing machines either manually or with help of auto feeders. They are fed in uniform stacks as per the guidelines adjusted dep ending upon the variety of the biscuit. Then, they are wrapped with packing mach ines and wrappers are sealed at both the ends with the help of heaters. Theses packs are then put into cartons and are ready to dispatch. Waste Management- There are two types of wastage that happens to occur in the pr ocess of manufacturing. First is the waste material fallen on the ground while molding the dough and cut ting it into the size and the shape of the biscuit. Such waste is 1% which is ma rginal and acceptable which goes into the total wastes. Second, is the broken biscuits which are collected in the tray of the multi-pack wrapping machine, since they are not packed and sold to the customers. Therefore, these wastes accumulated is then used for cattle feeding. OBJECTIVE OF THE INDUSTRIAL VISIT IILM believes that exposing the management students to actual business practices would enable them to test their text book knowledge with industrial practices a nd develop the required necessary analytical skills. It also familiarizes the st udents with environment in which a business unit operates to perform various act ivities. The interaction of students with line managers and other personnel help them understand the problems faced at the operational level. The objective of the Industrial Visit is to help students gain first hand inform ation regarding the functioning of the Industry, which helps the students with opportunities to plan, organize and engage in active learning experiences both i nside and outside the classroom. These visits represent important activities in any programme that contribute to the achievement of various essential learning outcomes and objectives. This exposure is a first hand opportunity to witness the start-to-end processes in an industrial unit as well as interact with the production managers spearhea ding the processes. Being a management student, such visits play a vital role in understanding the w orking of large scale organizations.

COMPANY PROFILE Year of Establishment : 1992 Nature of Business : Manufacturer, Retailer Major Markets : Indian Subcontinent, East Asia, Middle East and South East Asia Surya Food & Agro Ltd. was incorporated in November 1992 and commenced its comme rcial operations of manufacturing & selling of biscuits under the nameof Priyagol d in October 1993. Over a period, the company has established strong manufacturin g capabilities and has also invested substantially in developing consumer prefer ence for their products. The trademarks / brands Haq Se Maango & Priyagold have emer ged as one of the most powerful brands in the FMCG sector. The company is commit ted to invest in brands, manufacturing capabilities, deliverables and distributi on strength. Geographical PresenceSurya Foods, has three plants located in Greater Noida, Lucknow & Surat. They al so outsource some of their requirements to another plant located in Hyderabad. T he capacities has reached 1,50,000 MT p.a., which along with strong brand buildi ng and distribution capabilities has enabled them to command a sizable market sh are in the biscuit market despite competition from well-established players in t he industry. ProductsBadam Pista Biscuits Butter Bite Premium Biscuits Cashew Biscuits Cheese Cracker Biscuits Cnc Biscuits Cream Chocolate Biscuits Kids Cream Butter Biscuits Kids Cream Strawberry Biscuits Milk Biscuits Snacks Zig Zag Biscuits Marie Lite Biscuits

After establishing the foothold in biscuit industry, they continued to adopt str ategy to identify and commercialize profitable growth opportunities by leveragin g established brand and distribution network. Following this strategy, they diversified into manufacturing of fruit juices throu gh the wholly owned subsidiary Surya Fresh Foods Ltd. in January 2006.The manufact uring facility is located at Greater Noida, U.P. They have consciously invested in creating markets for fruit juices and have established brands such as Fresh Go ld & Treat. Both the brands are also well established and have penetrated into the fruit jui ce market aggressively by commanding considerable market share. They have also f orayed into the aerated fruit drink segment with the launch of Fresh Fizzy. They are also diversifying into manufacturing of chocolate, toffee and candies thr ough their wholly owned subsidiary Surya Processed Food Pvt. Ltd. at Haridwar, Utt arakhand. Priyagold wins Indian Railways Catering Tender

Our sales and marketing team has been working towards innovative and effective m arketing tools to remain competitive in a fiercely competitive environment. We h ave won a tender floated by Indian Railway Catering and Tourism Corporation Ltd. ( IRCTC), which allows us to set-up food kiosks for sale of our range of products i.e. biscuits & fruit juices and other future launches at Railway Stations sprea d across various cities in India. This will give us enhanced brand visibility an d would contribute considerably to the turnover. This initiative has added new d imensions to our marketing and distribution effort. StrategyTheir strategy of strengthening the brands especially the umbrella brand Priyagol d has resulted in creating immense brand recall value. They are continuing the ef fort with a scientific approach, which will result in growth of customer base, p rice premium, consumer loyalty which is expected to result in increased earning and ultimately enhancing enterprise value of the company. Thus, the company's manifesto is to build on the present strength created over the years and diversify into products and geographic portfolio. They aim at achievi ng profitable growth by penetrating into the consumption market to enhance marke t share by constantly innovating on product profile, investing in infrastructure thereby accelerating the top line growth to enhance the market share. They are also aggressively marketing the products in institutional category. Pre sently, products viz. biscuits and fruit juices are supplied to Airlines, Hotels , Railways, Canteens Stores Department (CSD) and organized retail outlets. PromotersShri Ballabh Prasad Agarwal (Chairman & Managing Director) He is the founder Director and Promoter of the company. He has about 35 years of experience in the business and industry. He is a well known personality in the biscuit manufacturing industry and has received U.P. Ratan award for his entrepren eurship. He is responsible for overall working of the company and is instrumenta l in making strategic decisions of the company. Under his leadership, the compan y has grown manifold and achieved an International Quality Crown Award, London 20 04 for best quality biscuit manufacturer. He is also the President of Indian Bisc uit Manufacturers Association (IBMA) and Vice President of All India Food Proces sors Association (AIFPA). AwardsChairman of Surya Food & Agro Ltd. Received the International Quality Crown Awar d in London. The Economic Times, Thursday 11 June 2008 Brand Equity Award-"Priyagold is the h ighest debutant at no 10." CompetitorsThe Company faces competition from various domestic as well as multi national co mpanies. The competitors of the Company includes multi national companies such asParle Biscuits Ltd. Britannia Industries Ltd. ITC Ltd. And domestic players especially in northern region of India such as Anmol Bakers Ltd. Super Snacks Pvt. Ltd. Bakemans Industries Ltd. Bakewell Agro Ltd. Cremica Agro Food Ltd. Gokul Food Pvt. Ltd. And other small unorganized sectors.

Market ShareThe Indian biscuit industry is the largest among all the food industries and has a turnover of around Rs 80bn and it is growing at the rate of 12-15% pa. Biscui t industry in India in the organized sector produces around 70% of the total pro duction, the balance 30% being contributed by the unorganized bakeries. The unor ganized share is shrinking over a period of time. The per capita consumption of biscuits in our country is only 2.1kg, compared to more than 10kg in the USA, UK and West European countries and above 4.25kg in South East Asian countries. Priya Gold is growing at a very fast rate and is the market leader in North & We st, and comprises a market share of ~12% in the biscuit segment, The fruit juice market is estimated at around Rs50bn with Rs12bn being in the or ganized sector. in juices segment, we are the third largest after Tropicana & Da bur. We are exporting biscuits, fruit juices, fruit drinks to Middle East, South Afri can countries and receiving offers from other Asian countries. Presently, our co ntribution of exports to our total revenues accounts for about 4-5%, but we are rapidly focusing on increasing the same. LEARNING OUTCOME The industrial visit was a great help to understand the working of the manufactu ring industry and how the complete process is worked on. It has helped us to get a clear view of how the biscuits are manufactured. It has also proved helpful in understanding the role of different people and ho w each of them contribute their bit in achieving organizational goals. It has helped us to become more aware of different departments in the organizati on, and what are the different career opportunities available in this particular sector. The visit has also made us clear about the quality standards maintained and also the efficiency in carrying out the process is well organized. It has also contributed us to understand what areas should we focus in the next two years. Personally, I would like to mention that as I am from human resource background, this visit was quite useful to me to understand the human resource of the manuf acturing unit. Till now, I have been a part of a financial firm where the employ ees were highly qualified, but here in the manufacturing unit people were skille d but not qualified. As an HR manager, you should know your employees well and also their role and re sponsibilities in the attaining of the organization goals. If I ever plan to work in sector like FMCG in future, I would be able to underst and the employees and their skill set which was only possible through this visit . And would be in a place where I will be able to manage the human skill efficie ntly. As a part of HR, your responsibilities start from the recruitment to the exit of the employee taking care of their stay in the organization throughout. And with out the complete information and knowledge this process can not be completed in manner. This visit also helped me to understand the organization hierarchy that is pract iced in this particular sector and the managerial practices followed. Therefore, I would like to conclude that the overall experience and exposure whi

ch was made available to us was quite helpful and will be useful to us in coming years. Would also like to thank the institute, the entire placement team, the faculty m embers and the staff at the Surya Foods, who had welcomed us and enabled our lea rning by sharing and giving us the complete knowledge about the plant. A Sincere thanks to Ms. Pragya Sonawane for guiding us althrough the visit.

REFERENCES http://www.google.com http://www.priyagold.com http://www.moneycontrol.com http://www.imagesfood.com http://mofpi.nic.in http://www.foodprocessing360.com http://www.thebiscuitdoctor.com http://www.indiainfoline.com