Hands On Training report-Rama Agro Foods Pvt. Ltd.

1. INTRODUCTION1.1 General Introduction:-

Agriculture is considered as the backbone of Indian economic. More than 50% of Indian

population thrives on agriculture. The Green Revolution and subsequent effort through the

application of science and technology for increasing food production in India have brought

self-reliance in food. The successful effort given by Government, State agriculture

universities, state department of agriculture and other organization through evaluation and

introduction of numerous, hybrid varieties of cereal, legume, fruit and vegetable and improve

management practices have resulted in increased food production.

The state government is providing lot of schemes, efforts to their farmers. The objectives

of these schemes are to generate employment opportunities in rural area to conserve soil and

water and improve social economic condition of farmer. The state has good research base

provide by Agriculture Universities in the state which produce good and well known

technology and have developed high yielding varieties of various fruit crops.

Through India is leading country in the production of fruits and vegetables which is more

than 10% of the world production whereas Maharashtra ranks as a leading state in

horticulture produce, the post-harvest wastage of fruit and vegetables are more than 30% due

to various reasons such as lack of infrastructure facilities, cold chain etc. and conversion of

fruit and vegetables for value addition is between 2 to3 %. Beside this current export of fruits

and vegetables and processed food product have not crossed the scale of 3% India’s total

export.

1.2 History of Company:-

Rama Agro Foods Pvt. Ltd. is located at Varve (Khurd) and is about 25 kms away from

Pune. The processing in plant started in May 2005 and vision is to manufacture all kinds of

processed Fruit Jams, Ketchup, Sauces, Syrup, Crushes, and Pickles of international

standards to fulfill the ever increasing food demand. Now the company is manufacturing

different Fruit jams, Ketchup, Sauce (Tomato).

Heading the organization is Mr. Ravindra Birole an able and efficient administration with a

shrewd business acumen and master in strategic planning.

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1.3 Mission:-

Rama agro is to produce and pack fruit products with highest regards to safety, nutrition

and taste by continues improvement in quality and food safety management system and

exceed customer’s expectations.

The company is trying to meet good food products to the customers. To prevent the

different kinds of diseases and fulfill requirement of seasonal fruit products available

throughout the year.

1.4 Date of Establishment

Rama Agro Foods Pvt. Ltd. Started in May 2005 and is located at Varve (Khurd) which

is about 25 kms away from Pune.

Table 1 Introduction about Company

2. OBJECTIVES OF TRAINING

To get involved professionally and intellectually in various work activities during

training period.

To get the practical knowledge of various products right from raw material receiving

to till finished goods dispatch.

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1. Name of the Company Rama Agro Foods Pvt. Ltd.

2. Address of Company Gat no.113, Varve (khurd), Pune- Satara road, Tal.Bhor Dist. - Pune.

3. Location At Varve (khurd), Tal.Bhor which is about 25 kms from Pune.

4. Certification ISO 9001:2008

To get acquaint with the various analytical tests which are carried out in a Quality

Assurance department.

To accept the challenges with open mind and positive viewpoint.

To adopt the hard work, competency and consistency.

To acquire the knowledge, new and techniques during training period.

3. ORGANIZATIONAL CHART

Managing Director

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HR and Purchase Manufacture Stores Account and

Administration Taxation

General Manager Store Incharge

Junior

Nominated office staff Production Manager Accountant

Quality Control Marketing

Manager

Fig. 1 Organization Chart

4. PRODUCTS OF RAMA AGRO FOODS

Jams:-

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Mixed Fruit Jam

Mango Jam

Strawberry Jam

Pineapple Jam

Sauces:-

Tomato sauce

Green chili sauce

Red chili sauce

Soya sauce

Ketchup:-

Tomato Ketchup

Canned Products:-

Mango Pulp

Sweet Corn Cream Style

Fruit Cocktail in Syrup

Tomato Puree

Pineapple Slices/ Tit-Bit in Syrup

Pickles:-

Mango Pickle

Mix Pickle

Lime Pickle

Lime Chili Pickle

Chili Pickle

Syrups:-

Orange Syrup

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Rose Syrup

Khus Syrup

Kokum Syrup

Crushes:-

Mango Crush

Pineapple Crush

Strawberry Crush

5. FACILITIES AVAILABLE

5.1 Land:-

Land selection is most important step while introducing a plant. The land selected for

Rama Agro is plane and away from the city. There is a reliable water supply. The building of

Rama agro is built on land at higher elevation to allow storm drainage away from processing

building.

Rama Agro Fruit Processing Pvt. Ltd is located in Pune (Varve. Tal. Bhor) Suitable land

and other facilities like water treatment, electricity, etc. are available here.

5.2 Building Construction:-

In the time construction of Rama Agro Processing Food there is proper sanitation

should be kept in mind right from the time when the building is planned.

1. The building has adequate space, with a logical unidirectional flow of materials, products

and personnel.

2. Physical separation of raw material from processed areas is done through walls &

compartments.

Walls:-

In plant walls are impervious to moisture, easily cleaned and constructed in order to

prevent the insect/rodent entry. They should be in good repair to prevent accumulation of

dust, dirt and vermin and to make cleaning easy. All cracks and crevices should be sealed to

prevent pests from entering.

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Floors:-The floors in working areas of food should be made of durable material because of the

following reasons:

1. They have to withstand heavy traffic.

2. Equipments are heavy duty and high weighted.

3. They are exposed to high temperatures.

The floors are easy to clean and resistant to effect of hot water, sanitizers and

detergents. They should be non-absorbent, grease resistant, dirt resistant, smooth, sealed and

pest resistant. Slope should be provided for self-draining of floors.

Ceilings:- All ceilings are free from cobwebs, cracks and flaking. They should not harbor dirt,

should be easily cleanable and should absorb moisture, especially in wet preparation areas.

Roof construction:- In Rama Agro, A logical roof type for precast concrete wall panel is a precast double

tee. This design is attractive and hygienic. Openings made for air removal should be

screened or sealed to prevent the entry of contaminants such as insects, water and dust.

Doors:-Doors provide simplest entry for pests and air-borne contaminants. A double-door

entry reduces airborne and pest contamination. Internal opening doors are provided with air

curtains whereas external doors have strip curtains & doors are kept closed when not in use as

are provided with auto door closures.

Windows:-Generally there is no need of installing windows if environment is controlled and

adequate lightening is provided. The windows in the plant are regularly cleaned and protect

form breakage. Windows are fitted with cleanable insect-proof screens thus minimizing

build-up of dirt.

Ventilation:-It refers to the maintaining atmospheric conditions which are comfortable and

healthful to human body. Proper ventilation is helpful because:

1. It makes the work place comfortable by reducing the temperature produced.

2. It prevents water of condensation from settling on walls and ceilings and dripping on food.

3. It prevents toxic fumes and gases from accumulating in the preparation areas.

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To maintain such conditions it is necessary to control the temperature humidity, air currents

and purity of air in the building.

Lighting:-There are proper lightening is available in the food processing areas because:

1. Helps the workers to work easily.

2. Improves overall quality and quantity of work.

Location of Equipment:-

All equipment’s are designed and located away from walls so as to facilitate good

hygiene practices and monitoring.

It ensures that it’s easy in operation, cleaning and maintenance.

Drains and Drainage:-

a. Drains are designed, constructed in concrete and located in such a way that the risk of

contamination of materials or products is avoided.

b. Drains have sufficient capacity to remove expected flow loads.

c. Drains pass over processing lines.

d. Drainage direction is not flowing from a contaminated area to a clean area.

6. POLICIES6.1 Quality and Food Safety Policy

“Rama Agro Foods Pvt. Ltd.” are committed in manufacturing of various Jams, Sauces, Ketchup and other Fruit and Vegetable products; committed to deliver safe, quality products to the upmost satisfaction of the domestic and international customers.

Establish objectives and targets and review them regularly to ensure better quality

products.

Commit our self for the continual improvement through innovation, technological up

gradation and active participation of associates.

Implement and maintain the food safety management system to deliver safe food

products.

Implement and maintain eco-friendly systems for disposal of waste by protecting,

preserving and enhancing the environmental conditions.

We are committed to manufacture & supply of pure hygienic, healthy products.

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We will continually improve in our customer satisfaction index &inour organizational

process by implementing the new technology, conducting the training to our staff &

continually improve in maintaining the healthy, hygienic clean environment

throughout the process at organizational premises to get more and more smiles of the

customer.

6.2 Environmental Policy

We are committed to sustainable development & continual improvement of environment around us.

We shall carry out all our activities keeping in line with our corporate mission & protect, preserve & enhance the environment. We shall achieve this through:

Conservation of scarce resources.

Increase in green cover. Prevention and control of pollution.

Striving to go beyond compliance to environmental available to public and interested

parties on demand legislation, regulations and other requirements.

Continually improve the environment and train all associates to build awareness on

environmental issues.

6.3 Health and Safety Policy

We are committed to securing health and safety of all our associates. We shall achieve this through:

Providing and maintaining safe plant and equipment.

Conducive work environment, sound manufacturing practices and adequate control on

the health & safety risks.

Judicious selection, placement and training of the associates and securing their

involvement.

7. DEPARTMENTS

7.1 Production Department

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The production department is a soul of an organization because its working efficiency

depends on other sector of company. Not only daily producing large quantity of production

but, also maintaining quality and hygiene of product is also important.

Functions of Production Department

Most of the man power is used in production department. The raw material availability

from store department also verifying quality of material, availability of energy source like

steam for cooking, electricity and availability of packaging material to finish good storage.

Production manager have production chart from which he manage man power as per

work. At early morning production executive check out cleaning of all equipments,

machineries, instrument, pipe lines and floor maintaining daily cleaning report. According to

the recipes preparation start batch wise and number of lot preparation decided. Production

officer frequently checks the temperature, pressure, and other parameters on processing

equipments as per desired product. Time of cooking, sequence of adding ingredients, time of

stirring is followed by workers, under the observation of production officer. Online quality

report (Annexure) is been filled during lot preparation to check parameters like TSS, acidity

and setting are within range of specification or not if all parameters are satisfactory then lot is

allowed for filling in containers.

During product filling temperature of product is a critical point so; it is strictly

maintained as per CCP’s for hot filling to avoid contamination. After product is filled in the

container randomly weight checking is done for ensuring Net weight of content of desired

product. It is the duty of supervisors to check online parameters or critical points like, foreign

matter in container ensure whether the line is working properly or not. After passing through

washing conveyors containers are observed for cleanliness. Further containers are conveyed

for labeling and printing. According to the size and numbers of products corrugated boxes are

used for packaging. These finished goods are transferred to dispatch store.

At the end of the day after processing of lots all equipments and machineries engaged

during processing are cleaned thoroughly.

Functions of Production Department

Utilization of man power

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Cleaning of processing area

Production planning

Quality inspection

Time management

Record Maintenance

7.2 Store Department

Store department is an important part of food industry because raw material for processing

which is perishable needs to be stored in good hygienic condition and suitable temperature.

Food Ingredients Store:

The raw ingredients which are basic component in food product are store in this

compartment. The raw ingredients like chemical preservatives, colors, flavors, thickeners are

stored separately to avoid mixing with other ingredients. Other dry ingredients like sugar,

salt, starches are stored on pallets above the ground level at dry place. Or small carboys near

production area for easy convey.

Packaging Material Store:

All the types of packaging material which need to be stored in dust free area for usage of

long period. Finished goods packaging required corrugated boxes, partitions and adhesive

tapes are stored classifying different products. Other packaging material like glass bottles,

tins, cans, crown, labels, PET bottles are stored in dust free area.

Working of Store Department

The main function of store department is to ensure the material for the quantity which is

been or ordered by purchase officer. Quantity is verified by mass in weight or quantity in

number. As material is received in factory store in charge get the goods receipt note. Store in

charge strictly verifies the quantity given on receipt note during unloading and stored in

storage area. After receiving packaging material and raw material the samples are sending to

quality department to verify the quality parameters for their approval.

7.3 Maintenance Department

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Maintenance department is like power house of company. The main source of energy

like electricity for machine, steam for cooking and many more are provided through

maintenance department. The main function of maintenance department is to regulate the

checkups and preventive maintenance of machineries and equipment’s used for processing.

Daily line setup as per the product is the preliminary work of the day which is done to

avoid breakdown during production line. Machine setting report is filled by maintenance

officer to avoid fluctuation in settings of machinery.

Maintenance officer do annual maintenance of all instrument, machineries and

equipment’s. Safety on electric circuit boards and equipment’s to avoid accidents.

Vessels testing of cooking vessels like kettles, filling tank etc. are done periodically to

observe leakages, corrosiveness and decrease in thickness of vessel coating.

Functions of Maintenance Department

Daily setup

Record maintenance

Energy supply

Maintenance of equipment’s and machineries

7.4 Quality Department

All issues related to the quality, hygiene and safety are concerned in quality department and

control measures are taken to secure the product quality.

Functions of Quality Department

1) Inspection of raw material and packaging material

Very first, instruments which are to be used like weighed balance, Standardization of

chemical, refractometer, glassware’s are calibrated. Received raw materials like pulps, spices,

raw fruits and vegetables and chemical preservatives are analyzed for their physical and

chemical properties according to the specification. If the raw material is not within the range

of desired specification then QC manager holds or rejects the whole batch of raw material

received.

The quality of packaging material is also an important factor of finished goods. The

specifications like size, shape, height, weight, thickness, etc. must be analyzed and approved

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if it is in specified range. Weight and volume of product affects if there is variation in the

specification of packaging material. If the packaging material is not desired specification then

QC manager holds or rejects the whole batch of packaging material received.

2) Cut out inspection report

The chemical, physical as well as sensory parameters of the finished good are analyzed on the

second day of production. Chemical properties like acidity and TSS are inspected. Also,

Physical parameters like Weighed and head space is inspected. Sensory parameters like color,

setting, consistency and taste of the product is analyzed.

3) Process audit

It is a monthly audit done as to verify the quantity of ingredients as per recipe and Standard

operating procedure. The weight or volume taken for lot preparation should be accurately

measured and preparation process for product must be in sequences to get desired consistency

and good quality product. Also, time required for cooking, proper mixing of ingredient and

holding of lot is been inspected in process audit.

4) Dispatch quality audit

It is a final audit conducted when the finished good is sending for dispatch. In this audit

things which are concerned to the consumer like mfg. date, price of product, batch no. and

time of production are checked. Also some critical parameters like label absent, no. of cases,

extraneous material, etc. are checked and remark. If the audit is not satisfactory then whole

lot is kept on hold or reworked.

5) Monitoring hygiene

Maintaining hygiene is a basic requirement in food industry. Hygiene ensures the safety for

consumption of food.

Sanitary practices for workers.

a) All workers provided with aprons, head caps, hand gloves and shoes to maintain their

personal hygiene.

b) At the entrance hand sanitizers is implementing for cleaning purpose.

c) Training and education is given to create awareness of personal hygiene and sanitation in

food processing plant.

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8. PRODUCT INTRODUCTION

Rama agro food Pvt. Ltd. Produces various range of products. Proper use of infrastructure

and man power makes them possible to daily finished goods up to 4 to 5 tones. Selection of

good quality of raw materials and instruments for processing is basis of factory success.

Considering kinds interest and providing nutrition through fruits. Rama food is producing

various types of sweet boiled fruit preserved i.e. jams with use of natural fruit pulps.

Also produced Chinese sauce like Green and Red chili Sauce and Soya Sauce. Tomato sauce

and ketchup which is prepared by fresh tomatoes is having great demand in market. Canned

products like Mango pulp, Tit-Bits in Syrup, Fruit cocktail in Syrup, Tomato puree and Sweet

Corn Cream Style are processed and packed in natural condition. Also the various products

prepared such as Pickles, Syrups, and Crushes etc.

9. PROCESSING

9.1 JAMSi) STRAWBERRY JAM

Raw materials

Strawberry pulp, sugar, pectin, acid, preservatives, color and flavor etc. received to

factory and it is observed for the quality parameters. If the raw material is not within the

quality parameters then the raw material is given back to the supplier.

Preparation of sugar syrup

Take a sugar as per formulation and add desired quantity of water. Solution is boiled

to get required degree of sugar syrup. When sugar is completely dissolves in water then add

preservative and acid. Stirring and boiling of sugar syrup is continued till TSS become

75oBrix. Then sugar syrup is filtered.

Mixing syrup and pulp

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Pulp and Sugar syrup is mixed as per recipe into the kettle. Continuous stirring and

boiling is done homogeneous mixing.

Addition of pectin

At desired temperature pectin slurry is added into the mixture of syrup and pulp. Pectin

get helps in proper setting of jam.

Addition of additives

Preservatives, acid, color and flavor is added to the mixture when TSS reaches to 68oBrix.

Quality inspection

Lot is checked for TSS, color, setting and taste. If it is satisfied then it is send for filling.

Filling

Glass bottles are inspected for foreign material, cracks and then bottles are washed with a hot water. Then jam is filling at desired temperature. Further these bottles are conveyed for washing and then transferred for coding and labeling.

Packaging and storage

Corrugated boxes are used as a tertiary packaging material. This is done by manually by workers. Then boxes are sent to the storage room at room temperature.

Flow Chart

Receiving of raw material (Strawberry pulp)

Boiling

Preparation of sugar syrup (75oBrix)

Filtration of syrup


Addition of pectin

Boiling

Checking end point (TSS 68oBrix)

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Addition of acid, flavor, color

Quality inspection

Filling

Bottling

Printing and labeling

Packaging

Storage

Fig. 2- Flow Chart of Strawberry Jam

Fig. 3 Strawberry Jam

ii) PINEAPPLE JAM

Raw materials

Pineapple pulp, sugar, pectin, acid, preservatives, color and flavor etc. received to

factory and it is observed for the quality parameters. If the raw material is not within the

quality parameters then the raw material is given back to the supplier.


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Take a sugar as per formulation and add desired quantity of water. Solution is boiled to get

required degree of sugar syrup. When sugar is completely dissolves in water then add






Addition of pectin





Quality inspection


Filling

Glass bottles are inspected for foreign material, cracks and then bottles are washed with a

hot water. Then jam is filling at desired temperature. Further these bottles are conveyed for

washing and then transferred for coding and labeling.


Corrugated boxes are used as a tertiary packaging material. This is done by manually by

workers. Then boxes are sent to the storage room at room temperature.

Flow Chart

Receiving of raw material (Pineapple pulp)

Boiling


Filtration of syrup

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Addition of pectin

Boiling



Quality inspection

Filling

Bottling


Packaging

Storage

Fig. 4- Flow Chart of Pineapple Jam

Fig. 5 Pineapple Jam

iii) MANGO JAM

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Raw materials

Mango pulp, sugar, pectin, acid, preservatives, color and flavor etc. received to factory

and it is observed for the quality parameters. If the raw material is not within the quality

parameters then the raw material is given back to the supplier.


Take a sugar as per formulation and add desired quantity of water. Solution is boiled to

get required degree of sugar syrup. When sugar is completely dissolves in water then add






Addition of pectin





Quality inspection


Filling

Glass bottles are inspected for foreign material, cracks and then bottles are washed with a hot water. Then jam is filling at desired temperature. Further these bottles are conveyed for washing and then transferred for coding and labeling.


Corrugated boxes are used as a tertiary packaging material. This is done by manually by

workers. Then boxes are sent to the storage room at room temperature.

Flow Chart

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Receiving of raw material (Mango pulp)

Boiling


Filtration of syrup


Addition of pectin

Boiling



Quality inspection

Filling

Bottling


Packaging and Storage

Fig. 6 - Flow Chart of Mango Jam

Fig. 7 Mango Jam

9.2 TOMATO SAUCE

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Receiving of raw materials

Aseptic tomato puree, sugar, salt, gums, acid, preservative, spice extract, corn flour etc. are

received. These raw materials are weighed accurately according to the formulation.

Processing

Tomato puree is added into the kettle. Boiling and stirring is continued. Then sugar is added

into kettle. Then simultaneously addition of other ingredients such as salt, gums, red chili

powder in the form of slurry. Then corn flour is added into the vessel when TSS is arriving at

28oBrix then addition of liquid spices.

Quality inspection

Quality checking is done for acidity, consistency, color and taste. Instrument used for TSS

measurement is refractometer.

Filling

Glass bottles are inspected for foreign material, cracks and then bottles are washed with a hot

water by manually. The whole product is transferred to the filling tank. Sauce is filled at

desired temperature. Then bottles are followed for crown corking on the same line.

Washing

Washing is done by passing through washing chamber. Bottles are capped after post drying

and send for labeling and packaging.

Labeling, Packaging and storage

Labeling is done manually by workers. Paper labels are used. Labeled bottles are packed in

corrugated boxes. These boxes are sending to storage area and stored at room temperature.

Flow Chart

Tomato puree

Addition of sugar

Cooking and stirring

Addition of gum slurry (Salt, Xanthan gum, Gaur gum, Red chili powder)

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Addition of corn flour and additive (Sodium Benzoate)

Addition of liquid spices

Addition of acid (Acetic acid)

Quality inspection

Filling

Washing


Packaging and Storage

Fig. 8 - Flow Chart of Tomato Sauce

Fig. 9 Tomato Sauce

9.3 TOMATO KETCHUP

Receiving of raw materials

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Aseptic tomato puree, sugar, salt, gums, acid, preservative, spice extract, corn flour etc. are

received. These raw materials are weighed accurately according to the formulation.

Processing

Tomato puree is added into the vessel. Boiling and stirring is continued. Then sugar is added

into vessel. Then simultaneously addition of other ingredients such as salt, gums, red chili

powder in the form of slurry. Then corn flour is added into the vessel when TSS is arriving at

33oBrixthen addition of liquid spices.

Quality inspection

Quality checking is done for acidity, consistency, color and taste. Instrument used for TSS

measurement is refractometer.

Filling

Glass bottles are inspected for foreign material, cracks and then bottles are washed with a hot

water by manually. The whole product is transferred to the filling tank. Ketchup is filled at

desired temperature. Then bottles are followed for crown corking on the same line.

Washing

Washing is done by passing through washing chamber. Bottles are capped after post drying

and send for labeling and packaging.

Labeling, Packaging and storage

Labeling is done manually by workers. Paper labels are used. Labeled bottles are packed in

corrugated boxes. These boxes are sending to storage area and stored at room temperature.

Flow Chart

Tomato puree

Addition of sugar


Addition of gum slurry (Salt, Xanthan gum, Red chili powder)


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Addition of corn flour and additive (Sodium Benzoate)

Addition of liquid spices

Addition of acid (Acetic acid)

Quality inspection

Filling

Washing


Packaging

Storage

Fig. 10 - Flow Chart of Tomato Ketchup

Fig. 11 Tomato Ketchup

9.4 TOMATO PUREE

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Produce of the concentration of tomato pulp obtained by fresh tomatoes, well ripe, having red sharp color, from suitable varieties, free from skin and seeds, chopped, pulped and refined. Produce exclusively from fresh tomatoes during the tomato season only.

Flow Chart

Ripe tomato receiving

Washing

Sorting

Crushing

Pulping in pulper

Juice Seed and Skin

Heating/ boiling till end point (8 to 10 o Brix)

Aseptic filling

Storage

Fig. 12 - Flow Chart of Tomato Puree

10. QUALITY EVALUATION AND ANALYTICAL PROCEDURES

Quality of food refers to the composite characteristic, which differentiate individuals

units and enable determination of the degree of acceptability by consumer. The overall

quality may be broken down in to component characteristics such as Colour, Texture, Flavour

and Nutritional value, freedom from harmful micro-organism and undesirable substances

each of these may be measured and controlled independently.

Quality is a measure of degree of excellence for the purpose of control. It may be

considered as specification. The precision and accuracy is the important requirement of

quality.

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As consumer become better informed & more sophisticated it is more vital for food industry

to developed effective quality assurance & sanitation programmed.

10.1 Sensory Quality:-

In this check the colour, smell, taste, &flavour.

a) Organoleptic Evaluation of Fruit Products:-

1. Objective: To evaluate the Organoleptic /Sensory parameters of fruit products

2. Procedure:a. Collect the sample bag of respective production.

b. Take approximate 100gm sample for testing.

c. Mix the sample well.

d. Check visually Colour, Sense the Flavour, and taste of the product.

e. Write down the findings in specified form.

10.2 Chemical Quality:-

In this we check the following parameters:-a) Determination of Acidity of Fruit Products:-

i. Objective:To determine acidity from the fruit products.

ii. Procedure:

a. Collect sample from respective stage of the production.

b. Mix the sample thoroughly.

c. Pour exactly 10gm of sample in a clean dry conical flask (250ml).

d. Shake the flask gently & dilute it with distilled water up to known volume.

e. Add few drops of 1% phenolphthalein solution as indicator.

f. Titrate this content with 0.1N NaOH solution, which is previously standardized.

g. Titrate until faint pink colour appears as an end point.

h. Note down the titrate value.

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iii. Calculations:-

Calculate the results as % of anhydrous citric acid or other acid by following method:

Formula:

Titre X Normality of alkali X Volume made up X

Equivalent Wt. of acid X 100

% Total acid = -------------------------------------------------------------------------

Vol. of Sample taken for estimation X Wt. or vol. of sample X 1000

b) Determination of Total Soluble Solids (TSS) in Fruit Products:-1. Objective:To determine total soluble solids/ brix present in the fruit products.

2. Procedure:

a. Brix is defined as % sucrose / sugar measured by brix hydrometer or ………

Refractometer.

b. The refractometer should be checked for accuracy before using.

c. Allow circulatingdistilled water through instrument for few minutes.

d. Note the temperature and refractive index of the distilled water.

e. Adjust the refractometer at zero scale.

f. Take spoonful of sample and place few drops of pulp on prism of refractometer.

g. Ensure that pulp temperature should be ambient.

h. Then see the scale of refractometer and note down the TSS/Brix present in the fruit

………Pulp.

11. SHELF LIFE

It is the time period from manufacturing until reaching the “best before date”. Best before

date” names the date until the product remains a defined quality. Food must be safe at the

“best before date”. Nutritional values, appearances, color; odour may have changed when

reaching the best before date as any food undergoes permanent change during storage.

“Use by date” is often used with food that perishes very easily and has especially high risk of

becoming “Unsafe” due to excessive storage. Food with the “use by date” must not be sold or

put into circulation for consumption in anyway after reaching this date.

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12. LABELLING

It is done for the identification of product, so it can be easily recognized by consumer.

For e.g. Mango jam shows fresh mango images in front of label so anyone can say that the

product is prepared using mango fruit. Like this label is representative of product and basic

ingredients of products are displayed through coloring or use of images on label.

Rama food is aware of market demand for their products so they are very conscious

about labeling. Use of good quality Laminated paper labels are used for labeling of

containers, which are stable up to disposal of container after consuming the product. Labels

give all legal information regarding product like ingredients, nutritional content,

manufacturing address, licensing number, weight of product, expiry date, veg., non veg. logo,

contact details, etc. which are strictly followed after ensuring legal attributes before labeling

on container.

Quality parameters like size, shape, thickness, coating workmanship of label are checked

by quality department and approval is given for use. Labels are perfect for individual product

with the use of color.

General requirements of labeling

1) Nutritional Information Nutritional Information or nutritional facts per 100 gm or 100ml of the products is given on the label as follows(i) Energy value in kcal;(ii) The amounts of protein, carbohydrate (specify quantity of sugar) and fat in gram (g)(iii) The amount of any other nutrient for which a nutrition or health claim is made should be declared. Like amount of saturated fatty acids, monounsaturated fatty acids and polyunsaturated fatty acids in gram (g)

2) Declaration Regarding Vegetarian or Non vegetarian food (i) Every package of food has given a declaration of veg or non-veg by a symbol and color code at below.

The symbol consists of a green and brown color filled circle for veg and non-veg food respectively.

Fig. 13 Veg. and Non -Veg. symbol

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3) Declaration Regarding Food Additives-(i) The following class titles are used together with the specific names or recognized International numerical identification

- Acidity Regulator, Anticaking Agent, Antioxidant, Color, Emulsifier, Gelling Agent, Preservative, Stabilizer, Sweetener, Thickener, etc. (ii) Addition of colorsWhen an extraneous coloring matter is to be added to any food product, it should be stated on label as follows.

CONTAINS PERMITTED NATURAL COLOR(S)

OR

CONTAINS PERMITTED SYNTHETIC FOOD COLOR(S)

OR

CONTAINS PERMITTED NATURAL AND SYNTHETIC FOOD COLOR(S)

(iii) Addition of FlavorsWhen an extraneous flavoring agent is to be added to any food product, it should be stated on label as follows.

CONTAINS ADDED FLAVORS (specify type of flavoring agent)

4) Name and Complete Address Of The Manufacturer

a. The name and complete address of the manufacturer and unit should be mentioned on label as well as packaging material.b. If any food product is imported into India, the packaging of food shall also carry the name and complete address of the improper in India.

5) Net Quantity

(i) Net quantity by weight or volume or number, shall be declared on every package of food.(ii) If food is packed in a liquid medium then label shall carry a declaration of the drained weight of the food.(iii) A batch number or lot number shall be given on label.6) Date Of Manufacturing Or Packing

The date, month and year in which the commodity is manufactured, packed shall be given on the label:

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If shelf life of the product is more than three month then the month and the year of manufacturing and packing shall be given as follows.

BEST BEFORE……..MONTHS FROM PACKAGING

13. PACKAGING In today’s society, packaging is pervasive and essential. It surrounds, enhances and

protects the goods we buy, from processing and manufacturing through handling and storage

to the final consumer. Without packaging, material handing handling would be a messy,

inefficient and costly exercise and modern consumer marketing would be virtually

impossible.

Packaging is of three types

1) Primary Packaging It consists of the packaging material which directly comes in contact to the product like

glass bottles, PET bottles, etc. all these material are sterilized using steam or hot water before

filling the product. The packaging material is inspected by quality department for its

specification.

2) Secondary Packaging It consists of the packaging material which does not come in direct contact of product.

These are involved after primary packaging. PM like labels, Plastic caps, tub lids, etc. these

PM acts as protective covering as well as displays product information.

3) Tertiary Packaging It consists of PM which involves outer most covering of products. It has safety functions

during transportation to avoid physical damage. PM like corrugated boxes, partitions and

Centre plate acts as cushioning agent. It does not allow container to collide with each other

during handling and transportation. It also provides product information.

Other than these basic packaging materials, various containers of different size and shaped

are used as per consumer demand and product attraction. For e.g. Mix fruit jam which is

packed in different volume and shape like 370 gm. glass bottles and 1 kg pet bottles. As an

old and famous brand in fruit and vegetable processing, Rama food uses optimum PM

considering the considering the demand of product in market and consumer satisfaction.

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14. INSTRUMENTATION/ EQUIPMENTS

a) Steam Jacketed Kettle

Fig. 14 Steam Jacketed Kettle

It is used for processing of jams, sauces and other food products for cooking and mixing.

The steam is used for cooking as a heating medium. Uniform heating, rapid heat transfer and easy control of heating rate through the

steam valve. The mountings such as pressure gauge, cleaning valve, vacuum feed pipes. It has the capacity to process 300 to 450 kg per batch.

b) Fruit Mill

Fig. 15 Fruit Mill

Fruit mill is using for crush the fruits to extract juice and pulp.

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c) Pulper Cum Finisher

Fig. 16 Pulper Cum Finisher

The pulper cum finisher is use for extract the pulp by separating skin and fiber of most fruits such as tomatoes and other fruit.

d) Fire Tube Boiler

Fig. 17 Fire Tube Boiler

Boiler is use to generate steam require for cooking. It is the only heating source for processing.

Fire tube boiler is used for steam production.

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The capacity of boiler is to produce 600 kg steam per hour. Fuel used for ignition of boiler is woods.

It requires 100 kg wood per hour and temperature 180oC to 200oC to generate the steam.

Steam is supplied through installed pipe lines to the production hall and valves are used to maintain steam pressure.

e) Crown Cork Machine

Fig. 18 Crown Cork Machine

It is used for air tight sealing. Crowns are placed manually on the top of the bottle. The bottle is transferred to the corking machine where the piston rod applies pressure

on the cork and the cork fits on the glass bottle.

15. PRODUCT SUPPLY CHAIN

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Factory

Dispatch

Fig. 19 Flow Sheet of Product Supply Chain

16. MARKETING STRATEGY

Rama Agro foods, the maker of jam, sauces, ketchups, etc. is looking for a presence for its products. The 9 years old brand, preliminary known in the Maharashtra, is targeting the local area (Pune). And also the product export in foreign country like Dubai.

The managing director Mr. Ravindra Birole says that the focus is now on the other regions like Mumbai, Goa. The strategy adopted by the company is to focus on cities offering high potential. The company is in the process of establishing a sales force to monitor the spread in these regions. The strategy is to have distributors for each city to ensure product placement in the supermarkets, general store as well as retail shops.

On brand-building activities, the company will concentrate on point- of- sales promotion. Events and exhibitions related to food are concentrated to promote the brand.

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City Depot

Distributor

Retailer

Consumer

17. CONCLUSION

RAMA AGRO FOODS PVT.LTD.VARVE (KHURD), PUNE. Plays an important role in Fruit and vegetable processing. All the workers are united working to achieve their goals. Their main aim to improve the quality and shelf life of the Jams, Sauce, Ketchup and other products. RAMA AGRO FOODS PVT.LTD.VARVE (KHURD), PUNE help to me and it was a great experience for me. It help to me enhance the professional side of career. I received the good co-operation and all help needed from the staff of RAMA AGRO FOODS PVT.LTD.VARVE (KHURD), PUNE. I thank all for the same, to provide training in their reputed organization.

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18. FEEDBACK

The 'In-plant Training' in RAMA AGRO FOODS PVT.LTD. was truly a great

experience and informative period. This training gave to me rich and valuable experience of

working in an organized industrial atmosphere. It has brought to me the conclusion that a

person can adjust to the condition available where he works and accepts the challenge placed

to him. I proud, that the training gave to me gain and maintains the human relation. It has

developed a lot of confidence in me and also has changed our point of view towards life.

Thus the experience which I gained during industrial training greatly helped in shaping

my personality and excellent insight into the working of an industrial plant.

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Hands On Training report-Rama Agro Foods Pvt. Ltd.

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Transcript of Hands On Training report-Rama Agro Foods Pvt. Ltd.