PRESENTATION ON INDUSTRIAL TRAINING AT:

WOCKHARDT LIFE SCIENCES, LALRU

BY:RIMALJIT KAUR 70700038B.TECH BIOTECH. 3rd YEAR,THAPAR UNIVERSITY.

INTRODUCTIONWOCKHARDT is the 5th largest research and technology oriented pharmaceutical and nutrition-based company and has a strong reputation for dynamism, innovation and growth. It employs over 4000 professionals across nine countries which have propelled consistent sales growth rate of 35-40%.

The Wockhardt life sciences at Lalru got established in 1997. This plant is dedicated to child and mother care. The nutrition based products for children from newborn to teenager are produced here. The plant also prepares critical care products and health products for ill and recovery patients. S

The plant has been set up with a capital of 42 crores. It has capacity to produce over 4000 tonnes of spray dried powder with sales potential of Rs. 100 crores.

QUALITY ASSURANCE DEPARTMENT

FUNCTIONS:

•The compliance of the product as per legal requirements and to ensure high quality product manufacturing.•To maintain the quality of products.•To carry out the various quality tests for raw as well as finished goods.•Readdress customer complaints and improve the product according to feedback from marketing.

CHEMICAL ANALYSIS PERFORMED :

1. CHEMICAL TESTING OF RAW MATERIAL:

FOLLOWING TESTS ARE PERFORMED FOR TESTING QUALITY OF RAW MILK:

1. FAT % TEST BY GERBER METHOD

2.SNF(SOLIDS NOT FATS) TEST BY LACTOMETER

3.ACIDITY TEST

4.COB TEST

5.TEST FOR ADULTERANTS (UREA, STARCH,SUGAR,GLUCOSE,SALT, NEUTRALIZER, FORMALIN, HYDROGEN PEROXIDE AND BORIC ACID.) 

RAW MATERIAL TESTS

MALTODEXTRIN •MOISTURE•pH•Dextrose equivalent•Starch test

CORN OIL/COCONUT OIL

•Peroxide value•Acid value•Saponification value

SUGAR• Moisture• Ash• Sulfated ash• clarity

RAW MATERIAL IS GROUPED AND EACH IS TESTED DIFFERENTLY:

EXTRUDED FLOUR(Rice flour, wheat flour, rice and moong blend, wheat flour with apple, wheat flour with vegetable

• Colour•Taste•Black particles•Particle size•Bulk density•Pap formation•Protein•Moisture•Fat•Ash•Mineral•pH•appearance

SOYA PROTEIN ISOLATE •Organoleptic tests•Moisture by oven and IR moisture balance•Ash•Fat•Sediment tests•protein

CASEIN • Moisture• Protein• fat•pH•Total acidity•Free acidity

WHEY PROTEIN CONCENTRATE • Moisture•Protein•Fat•pH

IN PROCESS PRODUCT QUALITY TESTING:

The product is tested for quality as per the desired parameters laid down by the SOP’s, the running sample is tested every 30 minutes.

The tests include:

Moisture by IR moisture balance Bulk density Sediment test Insolubility test Fat Appearance and test(organoleptic test)

During processing,the skimmed milk is tested every 15 minutes for which records are maintained. At the end of every shift, a closing sample from each tank is taken. 

TESTING FOR FINISHED PRODUCTS: There are 2 categories of products:1. Powdered product2. Ghee Selection of samples is done from the batch and tested for

complianace to quality specifications of company by foll.

Tests:

1.Appearnace2.Moisture3.Fat4.Protein5.Ash6.Minerals7.Vitamins8.Insolubility index9.Sediment index

TO TEST QUALITY OF GHEE ,FOLL. TESTS ARE PERFORMED:

RM-value( min. 28)

P-value(POLENSKE -VALUE(1.0-2.0))

Free fatty acids estimation( FFA % Oleic acid Max.)

BR-reading( at 40 degree C: 40-43)

CHEMICAL ANALYSIS OF WATER:

Water that is fed to boiler, cooling towers and water from effluent treatment plant are regularly chemically analyzed so as to ensure that water being fed is not hard( to avoid scaling).

Following tests are performed:1. pH2. Chloride content3. Total dissolved solid( TDS)4. Hardness5. Conductivity6. Alkalinity7. BOD8. COD

TESTING FOR SHELF LIFE OF PRODUCTS:

Control samples for each batch of products is selected and analyzed for each batch of products is selected and analyzed for following features:

Taste and appearance Mineral content Vitamin A Vitamin C Moisture Insolubility Free fat Peroxide value Lump formation Control samples are disposed off after 3 months after

expiry.

MICROBIOLOGICAL ANALYSIS AT THREE DIFFERENT LEVELS

MICROBIOLOGICAL ANALYSIS OF:

1. RAW MATERIAL

2. IN PROCESS PRODUCT

3. FINISHED PRODUCT

MICROBIOLOGICAL TESTS PERFORMED FOR RAW MATERIALS ARE:

1. STANDARD PLATE COUNT2. COLIFORM TEST3. YEAST AND MOULD COUNT The microbiological operations are performed as

per Standard Operating Principles laid by Company.

M.A. FOR IN PROCESS PRODUCT:

In process product samples are drawn aseptically from blending and bagging section, so that a regular eye can be kept on microbial load of product while manufacturing itself.

Tests performed for M.A. of in process products are similar to those for RAW MATERIALS( SPC and COLIFORM TEST)

M.A. FOR FINISHED PRODUCT

M.A. of finished product before dispatch in market which assures that finished product is a quality product and microbiologically safe for human consumption.

For this purpose, random selection of packaged product is done and microbiologically analyzed by foll. tests:

1. Standard plate count2. Coliform test3. Staphylococcus aureus( in 0.1gm)4. Shigella and Salmonella( in 25 gm)

MICROBIOLOGICAL TESTING FOR STERILITY OF EQUIPMENTS:

WITH SWAB: A swab consists of non absorbent cotton wool around notched

end of a metal wire. It is placed in 25 ml Phosphate solution and is sterilized.

Procedure:1. Rub the swab with pressure back and forth over the area to

be examined so that all parts are treated twice.2. After swabbing the swab is immersed in same tube and

then moving the swab mixes dilution.3. Take 1 ml of this dilution and add to 9 ml dilution.4. From this dilution transfer 1 ml to sterilized petri plates in

duplicates.5. Pour the agar medium into petri plates and rotate the

plates to mix the contents well.6. Allow the medium to solidify and incubate the plates at

37degree C(+/- 0.5degree C) for 48 hrs.7. After incubation count the no. of colonies.

PEST CONTROL AND FUMIGATION:

Pest control program is aimed at: denying entry

: denying shelter

: denying food

for control of rodents, rat baits /rat traps are used.

Chloryriphos (20% EC) diluted to 1%is sprayed every alternate day in the different areas as per the format.

FUMIGATION: Fumigation is a process of killing the micro organisms in air

through chemical agents so that this improves the quality of working environment under which we can manufacture and pack good quality products.

Reagents used: Formalin, potassium permanganate

PROCEDURE: First, seal the total area to be fumigated. Put the container with diluted formalin for 10 sq. feet area. This specified area requires 20 gm of potassium permangante

and 200 ml of formalin diluted three times with water. After putting this container add the cloth pillow containing

potassium permanganate. Close the door of the area properly. Open this area after three days.

Besides quality assurance, following deptts. Had a major role :

Production Stores Packaging E.T.P.( Effluent treatment plant) R & D Accounts

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