ACKNOWLEDGEMENT

Firstofall,Iam gratefultothealmightyGODforthegiftofknowledgewhichhasenabled
andestablishedmetoaccomplishthisreport.Iam verygratefultomyfamilyforthere
continuousloveandsupport.

Iam gratefulandexpressmysincerethankstoDr.RamadeviNimmanapalli(Professor
Incharge,BHURGSC)andDr.R.SMishra(coursecoordinator,BHURGSC)forprovidingme
withallthenecessaryfacilities.Ittakethisopportunitytorecordmysincerethankstoallthe
teachersespecially,Dr.AshokKumarYadav,Er.VedPrakashJaiswal,Dr.Sudhirkumar,Dr.
SanaFatima,Dr.PragyaMishra,Dr.SidharthKumarforexcellentteaching,immensesupport
andguidance.Ialsothanksmyseniorsforprovidingmevaluableinformation.Iexpressmy
specialthankstoalltheemployeesandassociatesoftheorganizationwhoinspiteofbeing
sobusy,helpedandguidedmeduringthistrainingperiod.

Sincerely,

AmritaSingh
 PREFACE
Thisreportcoverstheworkandeffortthathasdoneduringmyonemonthtrainingperiod,i.e.
from 26thDecember2019-26thJanuary2020atPALMYFOODPRODUCTPVT.
LTD.(SHIVPUR,TARNAVARANASI).Itincludesthedetailsaboutvarioussectionssuchas,
ProcessingsectionofthedifferenttypesofbreadandPackagingsectionofthebread.All
theexperiementwerecarriedoutusingSTANDARDOPERATINGPROCEDURES(SOPs).

ThePrinciplemotiveofthisreportistorevealmyPracticalaswelltheoreticalknowledge.

Here,Iam presentingthisreport.Ihavetriedmylevelbesttodoproperjustificationwithmy
workduringthistrainingperiod.
 PERSONALEXPERIENCE
Itwasagreatexperience.Iam honouredandconsidermyselfblessedforthegolden
opportunitygivenbythePALMYFOODPRODUCTS,VARANASI.Thisonemonthlearning
processhadenhancedmyprofessionalskills.Theenvironmentwasveryfriendlyandallthe
staffwashelpfulandcordial.

Iam alsogratefulforhavingachancetomeetsomanyhighlyprofessionalswholedme
throughthistrainingandincreasedmypracticalandtheoreticalknowledgeabout
Processing,MaintainingQualityControl/QualityAssuranceandAspeticPackag
 CONTENT
1: Introduction

-AboutPalmyFoodProduct

2: BreadMakingProcess

i) Mixing

ii) Forming

ii) Divider

iv) Hander-up

v) Interprover

vi) Molder

vii) Pressureboard

viii) Finalbread

3: Typesofbread

i) Brownbread

ii) Attabread

ii) Sandwichbread

iv) Premium longbread

v) Premium slicedbread

vi) Premium longbread

vii) Totalhealthpremium bread

viii) Specialtoastbread

ix) Multigrainbread

x) Butterandmilkbread

xi) Makhanmalaibread
 xii) Specialbread

xiii) Superrichbread

xiv) Milkbread

xv) Totalhealthsandwichbread 4:

BreadPackaging

5: Bunmakingprocess

6: Typesofbread

i) Topbun

ii) Premium milkbun ii)

Pav

7: Bunpackaging

8: Reference

INTRODUCTION

PALMYFOODPRODUCTSPRIVATELIMITED

AboutPalmyFoodProductsprivatelimited

PalmyFoodProductsPVTLTDwasregisteredon06May,1983.PalmyFoodProductsPvt
LtdCorporateIdentificationNumber(CIN)isU15117UP1983PTC006091,Registeration
Numberis006091.

Theirregisteredaddressonfileis301CityCentretheMallkanpur,UttarPradesh-208004
INDIA

PalmyFoodProductsPrivateLimitedcurrentlyhave3activeDirectors/partners:ShreeRam
Agarwal,SiddharthaAgarwal,RajnishChandraDixitandnootheractiveDirectors/Partners
inthecompanyexceptthese3officials.

PalmyFoodProductsPrivateLimitedIscurrentlyinActiveStatus.

COMPANYNAME: PALMYFOODPRODUCTSPRIVATELIMITED

CIN: U15117UP1983PTC006091

REGISTRATIONDETAILS: 06/05/1983
REGISTRATIONNO.: 006091

ADDRESS: 301CityCentretheMallkanpur,UttarPradesh-208004INDIA

COMPANYSTATUS: Active

ACTIVEDIRECTORS

DirectorName

ShreeRam Agarwal

SiddharthaAgarwal

RajnishChandraDixit

BREADMAKINGPROCESSCONSISTSOFSKILLSOF
BAKERANDAFEW SETPARAMETERSTOGETGOOD
QUALITYBREAD.
MANUFACTURING

-Breadmakingprocessflowchart

-Breadmanufacturingprocessconsistsoffollowingstagesbeforewegetthefinal
products.

-Mixingprocess

-Dividingprocess

-Intermediateproofing

-Moulding

-Panning

-Finalproofing

-Baking

-Depanning
-Cooling

-Slicing

Breadmanufacturingprofessionisasoldasstartingofhumancivilizationitistheoldest
profession.Wheneveryhousehavingitsownbakery.Nowwithmechanizationandwithnew
technologybreadsaremanufacturedinmassscales.

Worldoverwecanfindthousandsofbakeriespreparingvarietyofbreads.Welabelbread
withvariousnameslikebreadļoafŗotiķaboosetc.

Wewouldlimitourselvestotheseautomatesbreadplantsandtheirrelatedtopics.

BREADMANUFACTURINGPROCESS-STAGES
Preparationofingredients
-doughmixing

-bulkfermentation,spongetime.

-dividing(scaling)

-rounding

-moulding

-panning

-baking

-cooling

-slicingandpackaging

BREADPLANTANDMACHINERIES
:Floursifter

:Mixer

:Doughelevator

:Doughdivider

:Rounder-handerup

:Interprovers

:Moulder

:Pressureboard

:Finalprovers

:Countryoven/swingtrayoven/rotary/deck

:Depanner

:Coolingtunnel

:Slicers,baggingmachine,wrapperPKGmachine

MIXING
Mixingstartswithshiftingflourwithhelpofvibratorysifter.Flouristhencollectedinbowl
andthenweighed.Allingredientarethenaddedinbowlingredientsareflour,sugar,fat,salt,
yeast,GMSpowder,sodium stearcyllacitate,smpsolution,bio-bakeimprovers,ammounium
chloride,ascorbicacidcystiene,potbromated,calcium propionateandaceticacid.These
areaddedinstdproportionasperrequirement.

Afteradditionofallingredientsbowlismovedtospiralmixerwhereisdone.Waterisadded
indifferentqualitities.Mixingtimedependsonqualityofflouringeneralmixingtimecan
varyfrom 6-12min.

Undermixingandovermixingcanhavedirectimpactondoughconsistency.Doughquality
canbecheckedwithstretchingthedough,doughtemperatureismaintainedbetween
80degreef.

FORMING
Oncompletionofmixingdoughbowlisshiftedthroughtubinghoistandfrom thehoistbowl
istitledsoasdoughgoesintohopperofdividerhopper.

DIVIDER
Doughiscutintotwoequaldoughpiece.itsamechanicaldevicewhichusesacommon
cranktocranktocut,pushanddropdoughpiecesthroughdividertoconveyor.Volumeof
thedoughpiececanbeadjustedatdivider.Dividerisdefinedasno.ofdoughpieceper
min.

HANDERUP
From dividerthedoughpiecemovestohanderupwhichismechanicaldeviceconicalin
shapeonwhichdoughpiecetakescurvelinearpath.Ithasgotblowerattachedtoitwhich
continuouslyprovidesaironthepath.Basicfunctionofhanderupistogivedoughpiece
sphericalshapeandremovemoisturefrom surfaceofdoughpiece.

INTERPROOVER
Doughpiecesarethentransferredtobucketsofinterprovver,heredoughpieceareallowed
totravelfor5-6min.Thishelpsinrelaxationofdoughasitwouldhavestressdueto
mechanicalactiononitatdivider.

MOULDER
Ithasthreesetofroller.Thedoughpieceisallowedtopassthroughtheserollers.Now
doughpieceareslightlyflattened.

PRESSUREBOARD
Doughpiecesareturnedandfedintopressureboardwhereittakescylindershape.Airis
passedthroughtheboard.

FINALPROOVER
Thesedoughpiecesarethencarriedtoplatform wheretheselobesaretwistedandkeptin
moulds,twolobesaretwistedinonemouldboxasperwt.requiredlike400gmsor800
gmsloaves.

Mouldboxaregreasedpriortolobesbeingputintofinalprooverhasarrangementfor
steamswhichspreadsuniformlyinentirechamber.

Temperatureatfinalprooverismaintainedbetween36-38degreec.Humidityand
temperaturearemaintainedsoastogetmaximum ofyeastactivity.Precautionsaretaken
toseeifthereisoverorunderdevelopmentofdough.Speedcanbevariesatfinalproover.
Doughshouldraise¾thofthemouldis1320ccfor400gm and2700ccfor800gm loaves.
Traveloftraysislongitudinalinswinghtrayplantwhereasincontraytypeitisvertical.

Proovingtime=75min

Dependingupondesignwecandefinecapacityoffinalprooverascap/cycle:no.ofloaves/

No.ofracksxno.ofmouldsboxperrackxno.ofmouldineachbox.

Afterdoughhsbeendevelopedthesemouldboxarethentransferredmanuallytobaking
oven.

BREADPACKAGING
Specialcharacteristicofbreadwhichhastobeconsideredwhileselectingpackagingmatrial
are:
veryshortshelflife

softness

transportation

FOLLOWINGMATERIALAREUSEDBYBAKERYMANUFACTURERSFORBREAD

Normalweightofbreadpacksavailableare250g,400g,800g,1000g

Paperbags:Preferredbylocalbakerymanufacturersthesearesimplebagsaspersizeof
theloaves.Thesearenormallyusedforlocalpopulationwhoprefersloavesratherthan
slicesofbread.

Waxpaper:stillfewofbakerymanufacturesareusingit.Automaticsealingmachinesare
usedforsealing.

Hdpebags:breadsarepackedandsealingisdoneatoneside,flowwrapsmachinesare
usedinautomatedbreadmanufacturing.

Polybags:forproductslikebunpav,thesesortsofpackingmaterialareused

Thesearethenplacedinplastictraysspecificallymadeforhandlingofbread.Thesecreates
arethentransportedtotrtailshopandreturnedbacktothemanufacturers

Breadarepackedinmanydifferentform

Wholeloafinsinglepack

Slicedbreadindifferentconfigurationinflowwrapsarrangement

Verticalpouchforslicedbreadinpolybags

Sandwichesinflow pack

Bunsingroupof4/8/16flowpack

Breadrollsinflowpackformoreonbreadpackagingideasanddesign

FEW OTHERITEMSFORBREADPACKING

Bagclosure-Differenttypeofbagclosureareavailableinmarketthesere-usableandbit
trendyinuseTwinntieorWiretie:Thesetiesareusedtotieknotsinbreadbags,cost
effectivemethodtoclosebagsBreadhandlingplasticcrates:Thesecratesareusedto
handlebreadbagsduringprocess,packagingandtransportation.Differenttypesofplastic
traysareavailableforthispurpose.Breadbagsareplacedintothesetraysandareloadedin
vanstobeunloadedatretailsshops.Strengthisimportantcharacteristicsoftheseoftrays.

TYPESOFBREAD
1:BROWNBREAD
Mainingredientswholegrainflour(usuallyryeorwheat)ormolassesorcoffee

Foodenergy=260kcal(1089kj)

Cookbook=Brownbread Media=Brownbread

Brownbreadisadesignationoftengiventobreadsmadewithsignificantamountsofwhole
grainflour,usuallywheat,andsometimesdark-coloredingredientssuchasmolassesor
coffee.InCanadaandtheUnitedKingdom itsimplyreferstowholemealorwholewheat
bread,exceptinthemaintimes,whereitimpliesbreadmadewithmolasses.

Wholewheatfloursthatcontainsrawwheatgerm,Insteadoftoastedgerm,havehigher
levelsofglutathioneandthusaresaidtoresultinlowerloafvolumes.

Brownbreadisadesignationoftengiventobreadsmadewithsignificantamountsofwhole
grainflour,usuallywheatandsometimesdarkcoloredingredientssuchasmolassesor
coffee

Nutritionfacts:bread,wheatgerm ţoasted

Amountper=100grams

Calories=293%dailyvalue

Totalfat=3.3g5%

Saturatedfat=0.7g3%

Polyunsaturatedfat=0.8g

Monounsaturatedfat=1.4g

Cholesterol=1mg0%

Sodium =621mg25%

Potassium =285mg8%

Totalcarbohydrate=54g18%

Dietaryfibre=2.3g9%

Sugar=4.1g

Protein=11g22%

VitaminA=0% vitaminC=0%

Calcium=10% Iron=21% Magnesium =9%

VitaminD=0% VitaminB=6.5%

PercentDailyvaluesarebasedona2000caloriediet.Yourdailyvaluesmaybehigheror
lowerdependingonyourcalorieneeds.

PROCESS:Makingthedough.Inthebowlofastandmixerfittedwithadoughhookcmbine
the,sugaryeastandsaltmixforafewseconds,justuntilevenlycombined.Addegg,milk
and1/2cupstarter.Tum themixeronlowspeedandknead5min.

2:ATTABREAD
Breadmadewithwheatflourisnutritionsaswellasdelicioustoeat.Ifyoudon’tlikeeating
breadmadewithmaidathentrymakingfreshbrownathome.you”llsurelylikeit.

Ingredientsforwholewheatbrownbread

Wheatflour=2cup(300gm)

Oil=2tbsp

Activedryyeast=1tbsp

Salt=½tbsp

Sugar=1tbsp
 BUNMAKINGPROCESS
BunarebeingmadepopularbycoffeeandbakeryretailchainslikesofMcdonalda,burger
kings,subway,KFCetc.Bunsmanufacturingissimilartobreadmanufacturingexceptfor
bakingmouldswhichgivesitasphericalshape.Bunscouldbefoodbyitselfwithoutany
spreadsorfilling.

BunIngredients

Sweetbuns

Ingredients percentageofingredientsonthebasisofflour

Milk 10-12%

Shortening 8%

Sugar 10-15%

Wholeegg 5%

Yeast 8.5%

Salt 1.02%

BUNMANUFACTURINGPROCESS-STAGES

Preparationofingredients

-Doughmixing

-bulkfermentation

-dividing(scaling)

-Rounding

-Moulding

-Panning

-Baking

-Cooling

-Packaging

BUNMANUFACTURINGPLANT&MACHINERIES

MIXERDOUGHDIVIDERŖIUNDERHUNDERUP,INTERPROOVERS,MOULDER

PRESSUREBOARD,FINALPROOVERS,CONTRAYOVEN/SWINGTRAYOVEN
 MIXING
Mixingstartswithsiftingflourwithhelpofvibratorysifter.Flouristhencollectedinbowland
thwnweighed.Allingredientarethenaddedinbowl,ingredientsareflour,sugar,fat,
salt,yeastgms,powderşodium stearoyllacitatesmpsolution,bio-bake,improver,ammonium
chloride,ascorbicacidcystienepotbromated,calcium propionateandaceticacid.

Afteradditionofallingredientsbowlismovedtospiralmixerwhereisdone.Waterisadded
indifferentqualitities.Mixingtimedependsonqualityofflouringeneralmixingtimecan
varyfrom 6-12min.

Undermixingandovermixingcanhavedirectimpactondoughconsistency.Doughquality
canbecheckedwithstretchingthedough,doughtemperatureismaintainedbetween
80degreef-82deg.f

FORMING
Oncompletionofmixingdoughbowlisshiftedthroughtubinghoistandfrom thehoist
bowlistitledsoasdoughgoesintohopperofdividerhopper.

DIVIDER
Doughiscutintotwoequaldoughpiece.itsamechanicaldevicewhichusesacommon
cranktocranktocut,pushanddropdoughpiecesthroughdividertoconveyor.Volumeof
thedoughpiececanbeadjustedatdivider.Dividerisdefinedasno.ofdoughpieceper
min.

HANDERUP
From dividerthedoughpiecemovestohanderupwhichismechanicaldeviceconicalin
shapeonwhichdoughpiecetakescurvelinearpath.Ithasgotblowerattachedtoitwhich
continuouslyprovidesaironthepath.Basicfunctionofhanderupistogivedoughpiece
sphericalshapeandremovemoisturefrom surfaceofdoughpiece.

INTERPROOVER
Doughpiecesarethentransferredtobucketsofinterprovver,heredoughpieceare
allowedtotravelfor5-6min.Thishelpsinrelaxation ofdoughasitwouldhavestress
duetomechanicalactiononitatdivider.
 MOULDER
Ithasthreesetofroller.Thedoughpieceisallowedtopassthroughtheserollers.Now
doughpieceareslightlyflattened.

PRESSUREBOARD
Doughpiecesareturnedandfedintopressureboardwhereittakescylindershape.Airis
passedthroughtheboard.

FINALPROOVER
Thesedoughpiecesarethencarriedtoplatform wheretheselobesaretwistedandkeptin
moulds,twolobesaretwistedinonemouldboxasperwt.requiredlike400gmsor800
gmsloaves.

Mouldboxaregreasedpriortolobesbeingputintofinalprooverhasarrangementfor
steamswhichspreadsuniformlyinentirechamber.

Temperatureatfinalprooverismaintainedbetween36-38degreec.Humidityand
temperaturearemaintainedsoastogetmaximum ofyeastactivity.Precautionsaretaken
toseeifthereisoverorunderdevelopmentofdough.Speedcanbevariesatfinalproover.

Doughshouldraise¾thofthemouldis1320ccfor400gm and2700ccfor800gm loaves.

Traveloftraysislongitudinalinswinghtrayplantwhereasincontraytypeitisvertical.

Proovingtime=75min

Dependingupondesignwecandefinecapacityoffinalprooverascap/cycle:no.ofloaves/

No.ofracksxno.ofmouldsboxperrackxno.ofmouldineachbox.

Afterdoughhsbeendevelopedthesemouldboxarethentransferredmanuallytobaking
oven.
 BUNPACKAGING
Highspeedindustrialbakingequipment

BulkBunPackaging

TheStewartSystemsPillo-Pakbunpackagingsystem isanintegratedcombinationof
machinesdesignedtosliceandpackagebulkquantitiesofvarioustypesofbuns,rolls,amd
similarbakedproducts.

WiththePilli-Pakyougetanintegratedgroupofproducts,eachspecificallydesignedtodoits.

Arttopackageyourproductsandgetitreadyfordistributionintheexactconfigurationyou
want.Readonforaningredientsdepthdescriptionofeachofthecomponentsthatmake
upthePillo-pak.
 REFERENCES
Ihavegotalltheinformationfrom

~www.google.com

~www.wikipedia.com

~www.scribd.com