Haldiram

Haldiram

1. Training Presentation at Submitted By Akhilesh Goyal

2. The Haldiram story began in 1937 in Bikaner , a town in Rajasthan. The brand name HALDIRAM BHUJIAWALA was introduced in 1941. It was lead by three brothers Shri Moolchand, Shri Satyanarayan and Shri Ramesawar. In 1950, they expanded the business by establishing a small manufacturing unit of Sweets and Namkeens in Kolkata. In 1970, a large manufacturing unit was set up in Nagpur . The group has added another company in the name of Haldiram manufacturing Pvt. Ltd. At village kherki daula Gurgaon (Haryana ). PRODUCTS OFFERED : Haldiram Bhujia, Mini Samosa , Soan Papadi, Gulab Jamun, Rasgulla. INTRODUCTION

3. Haldiram’s began as a tiny shop in Bikaner . In1982, it has set up a shop in Delhi . Through hard work, complete dedication, uncompromising quality, - ‘HALDIRAM’ became a part of each family . Company Facts:

4. Haldiram’s various food products were manufactured in different sections. Following sections were under production area :- Ready to eat section. Moong dal and Bhujia section. Bakery section. Samosa section. Sweets section. Processing And Production

5. Various vegetable are manufactured in this section. These entire R.T.E. products goes in Haldiram’s Restaurants, Indian markets and also export to other countries where these have high demands. These products have long shelf life of about one to two years because they are sterile before packing. R.T.E. products are fulfilling the food requirement of Army in emergency time. But now these are also becomes need of our busy life. For completing all these requirements Haldiram’s gives many R.T.E. products which are as follows :- Ready To Eat Section

6. Haldiram’s Dal Makhani . Yellow Dal Tadka . Punjabi Kadhi Pakoda . Rajma Raseela . Purani Dilli ke choley . Aloo Mutter. Lazawab Mutter paneer . Mughlai Paneer Makhani . Nawabi Palak Paneer . Amchi Pao Bhaji .

7. Storage area. Pre-preparation area. Preparation area. Filling and sealing area. Retort. Incubation area. Packaging area. Ready To Eat Section Further Divided Into Following Parts:-

8. Raw Material Pre Preparation Preparation Quality Test Filling and Sealing Flow sheet RTE Products

9. Sterilization Incubation Packaging Dispatch

10. Storage area was used for storage of raw materials. The materials like masalas were used to stored in steel container and where as products like vegetables, milk, butter etc are stored in cold room whose temp was kept in the range 3 C to 16 C. STORAGE AREA

11. Here cutting and washing of vegetable, Paneer was taken by help of equipments or manual power. The equipments used were :- Vegetable washer: - Vegetables were washed with help of water which comes out with high pressure. Speedy cutter: - Vegetables were cut by two anticlockwise rotating blades presented in speedy cutter. About five to six kg. Material was cut at Once. Onion and Potato peeler: - These vegetables were peeled by help of corrugated surfaces present in the peeler. Pre-preparation Area

12. Paste makers: - These were used for making the paste of different vegetables like onion, spinach, green chili, tomato, Cashew nut etc. Centrifuge machine: - This machine was used for separation of water and boiled material like spinach which is used for making paste.

13. In preparation area cooking of raw material is done by using following equipments :- Boiler : - Boiler is used for boiling of water and other materials like spinach, dal, tomato etc. with the help of steam. Steam kettles: - These are used for cooking of products by help of steam. There is a temperature Indicator is present which indicates temperature of steam. Preparation Area

14. The finished products were prepared fill into retort able pouches by using Toyo Jidoki machine this machine requires the environment pressure 6 bar or more. There is temperature indicator which indicates gravy temp. and sealing temperature at the time of pouch filling. At this time, batch no. is also print on the pouches. Each ready to eat meal filled in retort able pouch weigh in between 300 to 317gm. because the packing of RTE product required to maintain a self life of one to two year. Filling and Sealing Area

15. Food was sterilized in retort at temperature 121 o C. A retort cycle has to take about 40 to 45 minute. This high temperature for sterilization commonly obtained from steam under pressure. The steam pressure of approximately 15 psi. required for 121 o C. The RTE food product was packed in retortable pouch because these pouches can with stand even in adverse condition of retorting. The advantages of pouches over cans and jars of equivalent volume include shorter retort time which can produce higher quality products, saving of energy, lighter weight, and increase compactness. Retortable pouches are constructed of three laminate layers consisting of:- Retort

16. An outer layer of polyester film for high temp. Resistance, strength and printability. A middle layer of aluminum foil for barrier properties. An inner layer of poly propylene film that provide heat seal integrity.

17. After sterilization, the pouches are incubated for about 15 days. Sample pouches goes for micro biological analysis. Then they undergo packing. Incubation

18. Incubated pouches were packed into mono cartoons. These monocartoon were packed into dispenser then in corrugated boxes for export. The dispenser was not used for market; here monocartoons are directly packed in corrugated box. The batch number, best before, manufactured date, maximum retail prize is printed on monocartoons . Two things printed on Dispenser was name of product, best before date. Total wt. of pouches packed was printed on corrugated box. Packaging

19. Haldiram’s Company was famous all over World for its Snacks, Bhujias etc. Here not only Moong dal but other dals like Urd , Mooth and a variety of bhujias were manufactured. These entire good quality products have their own taste make it valuable. Moong Dal and Bhujia Section

20. Moong Dal Soaking (Moisture 54%-56% For 1 hr 20 min) Frying (Temp 182-190C , Time 55-70 sec) PROCESS OF manufacturing of MOONG DAL

21. Salt Addition (On line) Finished Dal (Oil 20-22%, Salt 1.35%) Cooling Packaging

22. Washing :- Washing is mainly done to removal of dust, foreign materials and washing is mainly done in washing tank in which dal is washed through centrifuge process and after 40 min the dirt water is released and again clean water is added and washing is done for 20 min. In one washing tank there is 800kg dal was washed . Soaking :- After washing the soaking of moong dal is done for this the moong dal is soaked in water. Soaking is mainly done for 1hr 20min and the moisture level gain during soaking is about 54%-56%.

23. Conditioning :- After soaking the conditioning process is done for this the soaked dal is removed from water and transfer to conditioning tank. In conditioning tank the dal is kept overnight for 6-7hr. Frying :- After conditioning the dal is transfer to the fryer through belt conveyor. For frying the florigo frying machine is used and this machine is fully automated . T his automated fryer gives the output of 2750kg fried dal per hour. For frying process the cottonseed oil is used.

24. Salt Addition :- After frying the dal is pass through cooling conveyor which is directly connected to the fryer and after salt is added through rotary drum. The Salt is added about 1.35%. Finished dal :- After completing the process finished dal contain O il 20%-22% and moisture content 2.8%-3.1% . Af ter this process the finished dal i s passed for packaging through bucket conveyor.

25. Packaging :- For packaging of moong dal the polyethylene laminate and zip pouch is used. Polyethylene laminate is mainly used for small packaging like 18gm, 40gm and 200gm and for 400gm and 1kg namkeen zip pouches are used.

26. Mooth dal and Chana dal Cleaning Milling PROCESS OF manufacturing of BHUJIA

27. Masala Addition Dough Making (Moisture 35-42%) Frying (Temp 165-175C, Time 47-52 Sec) Finished Product (Oil 44-46%, Moisture 1-1.5%, Salt 1.6-1.8%)

28. Cooling (Temp 45C) Packaging (On line)

29. Cleaning :- It begins with cleaning process and for this various types of aspirators , blowers , and magnetic separator are used to remo v e dirt and small fine particle s and this process remove all the dust particles and foreign materials. Mixing :- For mixing process 250kg mooth dal and 50kg chana dal were taken and mixed together. Milling :- In this process the mixed dal are milled and is converted into gram flour or besan . This flour or besan is used for dough making in the next steps .

30. Masala Addition :- After milling of dal the masala is added in besan . For masala addition 2kg spices (1.3kg lougi mix powder, 0.1kg long powder and 0.6kg gram masala), 5kg salt and 2kg oil (cottonseed oil) are mixed with 120kg gram flour ( Besan ). Dough Making :- For dough making 38.7kg gram flour mix with 19 litre water and 1.5 litre cottonseed oil and mixed for 1.5min. The moisture content during dough making is about 35%-42%.

31. Frying :- Before frying the dough is passed through a n extruder which is operated at 30 RPM. During extruding process the dough is converted into bhujia shape and after that frying process take place. The frying is done for 47-52sec at 165-172C temperature. Gram Flour Mix For Dankoli :- For dankoli making we take 60kg gram flour and the addition of spices (black pepper 0.2kg, cardamom seed 0.2kg, garam masala 0.5kg, clove 0.1kg, and lougi mix 1kg) and 2.75 kg salt is added.

32. Dankoli Making :- For dankoli making 12.9kg gram flour mix is taken and 5 litre water is added and mixed for 5 min. And after that dankoli dough is passed through an extruder after which the frying takes place.

33. Finished Product :- The finished bhujia contain 44%-46% oil, moisture 1%-1.5% and salt 1.6%-1.8% and after this process the finished product is passed for packaging through bucket conveyor. Packaging :- For packaging polyethylene laminate and zip pouch is used. Polyethylene laminate is mainly used for small packaging like 20gm , 42gm and 200gm and for 400gm and 1kg bhujia zip pouches are used.

34. Haldiram’s bakery section produce various type of Breads like Bread Pao , Bread Pizza base, Bread brown, Patties, Kulcha , Cream rolls, Doughnut, Dinner roll, Cake, Chocolates, Pastries and many type of Cookies. Bakery Section

35. Quality Checks in Bakery Products Dough Moisture %. Over baked or under baked. Physical appearance i.e. Texture, Color etc. Baking temperature and time.

36. Products of this section mainly goes on Haldiram’s restaurants, domestic market . T he different products prepared in samosa section are samosa , suji and atta panipuri , rajkachori , masala kachori , dhokla and various types of chatnnies . Bhelpuri and panipuri are exported to other countries . Samosa section

37. Quality checks of samosa section products Quality of chatney . Raw material quality. Bhel mix quality. Size of panipuri and its moisture %. Seal quality of pouches. Product filling temp .

38. About three hundred types of sweets are manufactured in this section. All the sweets are prepared by using mava pindi except bangali sweets . Bengali sweets are prepared by using channa of cow’s milk. All these products have great demand in market at festival's depending of preparation area of sweets this section is further divided into sub section as following :- Kaju section This section provides different items prepared from Kaju like Kaju barfi , Kaju roll, Kaju gujia etc. Kaju barfi is the famous sweet of Haldiram’s company. Sweet’s section

39. Pinni section This section provides different products prepared by using flour like atta laddu , gajarpak , balusyahi , malpua etc. Malpua is the famous sweet of this section. Laddu section Various type of laddu’s prepared in this section like lal laddu , moti bundi laddu , kesar kalakand etc . Bengali sweet section Bengali sweets are prepared from channa of cow’s milk which provide softness to these products. The famous product of this section is rasgulla , rabri and badam milk etc.