AN EXPOSURE TO PRODUCTION AND QUALITY
CONTROL PROCEDURES
AT
SM FOOD MAKERS
BY
USAID GOHAR
(SBFOSC1M01023)
An Internship Report
In partial fulfilment of the requirement for the degree of
B.SC. (HONS.) FOOD SCIENCE & TECHNOLOGY
Department of Food Science & Technology
Faculty of Agriculture & Environment
The Islamia University of Bahawalpur
June 2023
To whom it may concern.
It is certified that Usaid Gohar joined us for internship program for 1 month.
He performed his work successfully and his report has been evaluated by:
Deputy Manager QE: _________________
Sir Umer Daraz sab
Manager QE: ____________________
Rana Muneer Ahmad SB
HR Manager: ____________________
Mrs Muzammil Saleem
TABLE OF CONTENT
SR. #
TITLE
PAGE
ABSTRACT
01
01
INTRODUCTION
02
02
REVIEW OF LITERATURE
05
03
MATERIALS AND METHODS
10
04
RESULTS AND DISCUSSION
19
05
OUTCOMES & CONCLUSION
26
REFERENCES
LIST OF TABLES
SR. #
TABLES
PAGE
4.1
HEDONIC SCALE
19
4.1.1
SENSORY EVALUATION OF Biscuits
20
4.1.2
SENSORY EVALUATION OF NIMKO
21
4.2.1
PERSONAL HYGIENE DATA OF DAY 1
23
4.2.2
PERSONAL HYGIENE DATA OF DAY 2
23
4.2.3
PERSONAL HYGIENE DATA OF DAY 3
24
4.2.4
PERSONAL HYGIENE DATA OF DAY 4
24
4.2.5
PERSONAL HYGIENE DATA FOR FOUR DAYS
24
LIST OF FIGURES
SR. #
FIGURES
PAGE
4.1.1
SENSORY EVALUATION OF BISCUITS
20
4.1.2
SENSORY EVALUATION OF NIMKO
21
TERMS AND DEFINITION
Snack
A snack is a small portion of food eaten between meals. Snacks come in a variety of forms
including packaged snack foods and other processed foods, as well as items made from fresh ingredients
at home.
Extrusion
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material
through a die of the desired cross-section.
Kneading
Kneading is working a dough mixture to form a smooth and cohesive mass.
Mixing
The process involves combining two or more separate components to produce a certain level of
homogeneity.
Drying
We defined drying as the application of heat under controlled conditions, to remove the water
present in foods by evaporation to yield solid products.
Baking
Baking is a method of preparing food that uses dry heat, typically in an oven, but can also be
done in hot ashes, or on hot stones.
Seasoning
Seasoning is supplementing food through herbs, salts, or spices intended to enhance a particular
flavour.
Packaging
Food packaging is the enclosing of food to protect it from damage, contamination and spoilages.
Pest attacks, and tampering during transport and storage.
Grinding
It is breaking solid food items into smaller particles.
Moulding
Manufacturing is by shaping liquid or pliable raw material using a rigid frame called mould or
matrix.
Free Fatty Acids
By hydrolysis of fats and oil, free fatty acids are produced.
Moisture Meter
It is a device used to measure the percentage of water in a substance.
Total Polar Material
It refers to all products present in frying oil because of oxidation processes, including free fatty
acids, products of low molecular weigh decomposition, and polymerized substances.
ABSTRACT
The snacks manufacturing process mainly consists of mixing the flour, extraction from extrusion,
heating in an oven or frying, seasoning and packaging. The structure of snacks is formed through various
steps of its making process, among which those related to frying are particularly important. SM Food
Makers processes different kinds of snack products by using high-quality ingredients. During two weeks,
I did all processes required in snack production (Biscuits and Nimko) along with the sensory evaluation
of snack products. SM Food Makers is one of the leading snacks producing industries in the southern
Punjab city of Multan which is involved in the production of high-quality products on a scientific basis.
In the SM Food Makers industry, different products such as Biscuits and Nimko, are manufactured.
During the period of internship, different technological applications regarding snack production were
performed. Whole ingredients of all products, flour mixing, dough mixing time, extrusion heating, oven
heating and frying of differently weighed varieties of snacks, frying time, spice mixing, sack storage,
and packaging were also studied. The purpose of this internship is to study the production and processing
of snack food and its quality in SM Food Makers. The main motive of this internship is to learn, analyze
and evaluate the quality and safety of food products in the food Industry. We did our internship at SM
Food Makers Multan, for two weeks to conduct the required study.
Keywords:
Extrusion; mixing; Frying.
1
CHAPTER 1
INTRODUCTION
1.1 Background
S.M Food established in the year 2000, is primarily engaged in manufacturing food products I.e.
.biscuits, wafers, chocolates, toffees, candies, Choco bounties, Nikos, and bubble gums. Since its
inception, S.M Foods has established itself as one of the best biscuits and confectionery products
manufacturing companies in Pakistan. S.M Foods Limited's brands are available in every nook and
corner of Pakistan and as well as. SM is running different businesses with popular brands like Gibbs and
Gibbs Gold it has opened its outlets in significant urban areas in Pakistan. Distinctive divisions are
functioning admirably to accomplish the key points of the organization. They are embracing the most
recent Management Information System (MIS) to get to the information that outcomes in creating
auspicious results for various divisions. The PESTEL investigation demonstrates that the organization
has lived far from any sort of difficulties that may have influenced the organization's goodwill by
satisfying the legitimate, natural necessities and utilizing worldwide money-related guidelines as a part
of the creation of budgetary explanations. The SWOT investigation shows that qualities are more
strength in number when contrasted with shortcomings and dangers and that demonstrates the
organization well knows its position and stays up with the latest. Still, there are a few does not have that
organization ought to overcome to get extreme results.
1.2 Snack Food
Consumers buy more than $6.5 billion worth of flavoured salty snacks in the United States annually.
This is an incredibly competitive business where small regional chippers and national snack food giants
go toe to toe in competition for a share of the snacking consumer’s money. Americans are snacking more
than ever before. There is a growing population of Americans who snack throughout the day with no sitdown meals at all. It should be no surprise this translates into big opportunities for snack companies.
However, snack consumers are demanding. They want variety and many options. Developing a new
snack brand is difficult. New equipment and ingredient have to be purchased. In addition, advertising
budgets must be increased to inform consumers about the new brand and persuade them to buy it. Line
extensions allow the snack manufacturer to have a portfolio of products that appeal to a broad range of
consumers at a lower cost. The most popular flavours for salty snack seasonings have been Cheese,
BBQ, Sour Cream Onion, and Ranch. These four seasonings form the basis for the flavour portfolios of
most snack food brands. Many snack food companies include two or more of these flavour profiles in
each new brand they introduce. For example, BBQ seasonings developed in the mid-1960s were typically
hickory smoke types with high levels of tortilla yeast, paprika, and Spices. In the late 1980s, many
companies reformulated their BBQ seasonings to which from hickory smoke to mesquite smoke, and
made the flavour much Sweeter by introducing sugar, dextrose, or honey. In the 1990s, they adjusted
many BBQ Formulas to be spicier with more red pepper and more acidity. Similar evolutions have
occurred for each of the classic seasoning types over the last 20 years, with each profile changing slightly
to match the changing tastes of the snack consumer. Successful new snack seasonings often use familiar
flavours and combine them in creative ways. Cheese powder, tomato onion, and garlic appear in almost
every ingredient statement. These Ingredients appear in seasoning formulas like BBQ, nacho cheese,
pizza, taco, Chili cheese, or ranch.
2
Fig 1.1: Organizational Structure
3
1.3 Processes of Industry
The raw material used for snacks is received at the factory and analyzed. Most of the ingredients in
a snack are the same. There are differences in processing. All raw materials are analyzed and those
materials, which fulfil the standard requirements, are then used. If raw material passes the reception tests,
then it is stored in a storage room. Proper storage is necessary to avoid contamination. Scale all
ingredients accurately and sift the dry ingredients then mix of material according to need. Then this
batter or dough is shifted to the extruders of moulding. After giving different shapes of different products,
it is sun-dried or stored in controlled atmosphere storage rooms. Then the process of frying or oven
baking starts which further goes for seasoning. The final packaging is done and stored in the warehouse.
In the end, the product is ready for transportation as needed in different places.
1.4 Aims and Objectives
The purpose of the internship is to learn about the production and quality control parameters in the
SM Food Makers. The internship program will increase our earning potential upon graduation and build
strength, spirit, and self-confidence in our life. It can also build our good communication skills with a
group of workers and staff members, learn proper behaviour of corporate life in the industrial sector, and
enhance our ability to improve our creative skills. Our internship aim is to know about professional life.
 To check the workers & working according to SOPs.
 To check the good working relationships with the organization’s employees.
 To check how theoretical knowledge works practically.
 To build better teamwork abilities.
4
CHAPTER 2
REVIEW OF LITERATURE
2.1 CLASSIFICATION OF SNACKS
They classify snacks into three categories:
 First-generation snacks are produced by simple extrusion without further processing
like popcorn, potato chips, nuts, etc.
 Second-generation snacks are high-fiber, high-protein snack products made of extruded
materials like puffed corn products, corn chips, curls, and balls.
 Third-generation snacks refer to fried and flavoured snacks produced from extruded
pellets. Snack pellets are non-expanded and made from raw materials like potatoes,
cereals, and vegetable powder.
2.1.1 Biscuits
Biscuits are a type of baked goods that are typically small, flat, and round. They are made from
a mixture of flour, fat (such as butter or lard), and a leavening agent (such as baking powder or baking
soda). Biscuits can be sweet or savoury, depending on the recipe and the intended use. In some countries,
such as the United States, biscuits are a popular breakfast food and are often served with gravy or butter
and jam. In other countries, such as the United Kingdom, biscuits are a type of cookie and are often
enjoyed as a sweet snack with tea or coffee.
2.1.2 Nimko
It is a type of snack comprising a variable mixture of saltish ingredients, such as peanuts,
chickpeas, etc. It is a variety of snacks comprised of one or more cooked spicy snack comprises usually
flour, starch, colours, and water, placed inside a flour mixer.
2.2 TECHNOLOGIES USED IN THE SM FOODS MAKER
They used the following technologies used in snack processing at the industrial level.
2.2.1 Mixing
They mix all the ingredients in a mixing machine with a measured amount. The mixing machine
mixes all ingredients properly. Powder or solid mixing allows getting a homogeneous mixture of
different components and one of the process steps adds more value.
2.2.2 Extrusion
Extrusion is a process that combines several unit operations including mixing cooking, kneading,
shaping, and forming. Extruders usually have three stages:
 First is the feeding section which allows the material to enter the extruder at a relatively smooth
rate. This is a part that maintains a relatively low temperature so that the blockage of feeding
material can be stopped.
 Second part is referred to as the compression section, wherein the melt is formed and the pressure
is purposely increased.
 Last part is the metering section close to the exit of the extruder. Its main function is to maintain
a uniform flow out of material in the extruder.
5
2.2.3 Frying
The extruded snacks are fried in frying chambers, for frying vegetable oil is used. They reduced
the moisture level from 8% to 2%, during frying. They fry snacks at a limited temperature and time.
2.2.4 Baking
Another example of the extruded expanded snack foods is baked collections (e.g., potato sticks,
onion rings, and baked corn curls). They can be made with different tuber flours and cereal grains. Bran,
cellulose, fibers, and protein can be blended with a cereal grain (making up to 20% of the material) to
make healthy snack foods. As for potato sticks, they are usually made by mixing potato flour with rice
or corn flour. The baking process involves cooking snacks with heat transferred through the air by
convection, conduction, or radiation. The effectiveness of each of these methods depends on the oven
type and product design.
2.2.5 Drying
Certain products, like puffed snacks, become crispy through the drying process. These snacks
need to be dried after the extrusion process until the moisture level drops under 4%. This way, puffed
snacks gain satisfactory texture and storage stability. Drying process control plays a significant role in
ensuring that moisture does not go above or below the determined level.
2.2.6 Seasoning
The substances added to other foods enhance their flavour and smell, such as salt, pepper, herbs,
spices, oils, and a spoonful of vinegar to name a few. Although the term "seasoning" and "flavouring"
are most often considered to be the same, to some they are separate terms. However, it is generally felt
that any substance that can be added to a recipe to provide the desired flavour, such as sweet, spicy,
intensely hot, sour, tangy, or earthy, is added as a seasoning. Sour, tangy, or earthy, is added as a
seasoning.
2.2.7 Packaging
Snack’s packaging has shifted from share-size bags to single-portion packages. This change
requires advanced packaging machines that provide flexible packaging materials, sizes, high speeds, and
lower reject rates. By implementing these innovative systems, snack food companies will be able to
implement better packaging materials and smaller sizes that comply with the WHO guidelines(Snack
Foods Processing - Google Books, n.d.).
2.3 SNACKS INGREDIENTS AND THEIR FUNCTIONS
2.3.1 Wheat Flour
Wheat flour is a very important and basic ingredient in the snack industry,
which can impart a unique appearance and characteristics to products. Wheat
flour is produced by milling the whole-wheat grain, which contains germ, bran
& endosperm, but endosperm is used & is separated from germ & bran, which
is called white flour.
 A powdery substance is produced by finely grinding grain through
milling.
 Good binding.
 Good expansion.
 Contains gluten (good binder)
 Most widely available starch source.
6
2.3.2 Flavour
The flavour is the most important criterion in the classification of ingredients,
probably there are more but it is the most fundamental to start with the expected
flavoursome. It is a basic attribute in the snack context. We divide it into several
principal categories.
a. Acidic
Most of the raw material contains other flavours like essential oil and natural flavours that give them
acidity. The acid involved is characteristic of raw material and can range in pH value from bland (lactic
acid) to sharp (acetic acid) taste.
b. Salty
Salt is present as an ingredient or additionally added for preservation or dehydration purpose.
Another purpose is to use as subliminal which removes the “off flavour” in some cereals or raw materials.
c. Sweet
Sweeteners are the most economically used flavour in any food or beverage. It is a major problem to
choose a horse for the course for sweeteners in snack products. The principal constraints are (a) quality
of sweeteners (b) cost and availability (c) stability in manufacturing and final product context are all
related to sweetness level.
2.3.3 Food Colours
Something accepted the need and the advantages of colours in the snack food
industry and food ingredients. Some foods are improved much by having their
dullness removed by whitening. So colours used within strict limits is progressively
accepted. In the food industry colour particularly, contributes to appeal and
recognition.




Should be within limits.
The amount varies with the product.
Gives the products an appealing appearance.
Remove the dullness.
2.3.4 Water
Water is an important ingredient used in the food industry. It would be
impossible to produce snacks without water in some form. We usually add water
to assist in mixing the flour or dough making. It facilitates the mixing of other
ingredients and other steps of processing.
 Basic ingredient.
 Solvent for the dispersion of salt, sugar, and other ingredients.
 Hydration of protein to form gluten.
 Controls the consistency of the dough.
 The amount varies according to the product.
7
2.3.5 Sugar
Chemically it is known as sucrose. In snack production, the amount of sugar
depends on the type of snack or product to be manufactured. In Biscuit production,
2% sugar is used. Snacks-making needs white crystalline sugar. Powdered sugar
may also be used. The basic function of sugar is that it provides sweetness. Besides
this, it enhances flavour and aroma.




A basic ingredient in snack processing.
The amount varies according to the product.
Keeps moisture and prolongs freshness.
Improves the grain and texture of the snacks.
2.3.6 Salt
We use salt for flavour and taste. It brings about the taste of other ingredients.
Table salt should have the following characteristics for snacks. It should be
completely soluble in water. It should give a clear solution. The cloudy solution
shows certain impurities. It is mainly added to taste. Used for flavour & flavourenhancing properties.
 Used for taste and toughens the gluten.
 Effect on colour and keeping quality.
2.3.7 Starch
Starch is in many green-leaf plants. During, dormancy and germination it
serves as food for energy in plants and humans. It is an important ingredient for
the food industry, used to improve the sensory and nutritional quality of food.
Starch derivatives and starches have a long history of use in food like snacks. We
mainly used it as a functional ingredient to help snacks achieve various textural
attributes‚ suspend solid‚ yield decide appearance and control moisture.
 Improved crispness.
 Reduced oil pickup.
 Increased expansion.
 For taste and appealing reduced fat products.
2.3.8 Peanut Grits
Peanut grits are particles of the endosperm. They contain 0.7-1% oil and
are low in fiber. Snacks‚ breakfast cereal and brewing industries use these grits of
various granulations. In, some countries it also used peanut grits as a side dish for
breakfast. They processed peanut grits through extrusion cooking to produce
maize balls. The shape of the ball or puffed extruded depends on the die‚ cut-off
knife speed‚ operational temperature and other factors.
8
2.4 SENSORY EVALUATION
A scientific discipline that applies principles of experimental design and statistical analysis to the use
of human senses (sight, smell, taste, touch, and hearing) to evaluate consumer products is called sensory
evaluation. The development of wholesome and nutritious fiber-rich food products with acceptable
functional and sensory quality is a major industrial concern, seeking to capture consumers’ interest in
healthy and functional foods (Singh et al. 2012). Experienced persons look at products and judge about
physical texture and structure of the product. In the same way, experienced persons smell that product
and evaluate it based on aroma/smell. The smell tells us about mainly the rancidity of the product. Touch
is the main and important factor that describes the texture and physical structure of the product. Touching
it indicates the roughness and plainness of the product. Trained persons evaluate this on the base of
touch. Taste is another method that shows if that product is fully baked or not. The production manager
and Assistant Quality Controller asked the internee to check the product quality by sensory evaluation.
The internee tries its best to check the quality of baked food but to some extent, the internee was to
succeed. As it is a time-consuming procedure with gained experienced gaining procedure, but the
internee has not it, yet very low. But during their tenure at SM Food Makers internees gained some
experience and skills, which will be valuable in their future careers.
2.5 SANITATION AND CLEANING
Sanitation and Cleaning are of great concern during/after processing. Usually, two methods are applied
for sanitation and cleaning purposes, one is CIP (Clean in Place) and the other is COP (Clean out of
Place). The former is practised daily but later after a month. A detergent that is used during sanitation is
Chlorine 100-150ppm to sanitize the equipment. The amount of chlorine is directly proportional to the
time exposed. Personal hygiene practises should be adopted that tells that every person should bath daily,
complete dressing during work, have no ring or bracelet during work, nails should be cut, and medical
checkup should be done by the industry at the time of hiring staff/labour (Centre for Affordable water
and sanitation technology)(Sustainability, Eating Habits and Sustainable Food Production in the
Development of Innovative “Healthy” Snacks, n.d.)
2.6 DEPARTMENTS AND SECTIONS
2.6.1 Departments








Quality Assurance Department.
Production Department.
Human Resource Department.
Administration Department.
Sales and Marketing Department.
Accounts Department.
Mechanical Department.
Resources and Development.
2.6.2 Sections







Raw Materials Storage.
Packing Wrap Store.
Grinding Unit.
Fryer Section.
Extruder Section.
Fried Products Store.
Packing Section.
9
CHAPTER 3
MATERIALS & METHODS
3.1 Extruder (Double Screw Extruder)
Inverter-based feeding, main driving device, and rotary device
provide a more powerful and stable drive at low electricity
consumption. They constructed s screw from alloy steel having a
longer life. It can assemble freely a screw according to different
materials and products. A lubrication system can lower power
consumption and prolong the machine component’s life. A
Photoelectric sensor and double-screw feeder can forcibly and equally
control the feeding. Double screw feeds forcibly material. The double screw can clean itself
automatically. The gliding system can adjust the knives accurately and quickly. Suitable for flour-based
2D & 3D pellet products and Pops.
3.2 Batch Type Fryer
Compact frying, de-oiling, and conveying design. Two
control ways, manual and automatic make operation flexible. PLC
centrally controls the frying process in high automation. Swift
temperature control through thermal efficient diesel/gas burner at low
power consumption. The complete material of construction is
Stainless Steel. Reduces labour force in frying compared to some
traditional batch fryers. Latest Oil Heating Technology. Heat-free
working environment. Over, 55% fuel saving as compared to a
traditional system. Low maintenance. Less power consumption compares to traditional batch fryers.
Easy installation. Sturdy construction.
3.3 Vertical Packing Machine
Advance design with simple operation. With a touch screen
PLC control system, low fault rate. With frequency change speed, the
sealing knife opens automatically when a machine is shut down which
saves material. Bag-making, filling, measuring, sealing, printing, and
product conveying in one operation. Suitable for packing granular,
sheet, strip, and powder, such as biscuits, rice, potato, chips, shrimp,
pet food, jelly, peanut, coffee, milk, and other products. It featured this
machine with a compact structure, stable & easy operation, and
convenient repair. This machine adopts programmable control super large touchable screen. It featured
a servo film conveyor system with accurate posting and looking. This machine can finish all processes
automatically from measuring, filling, bag making, and date printing to finished production conveyance.
The turn-out function for a single bag or several linked bags is available, according to customer
requirements. It can equip this machine with a whole device and gusseting device.
10
3.4 Heat Exchanger
Direct Heating models for Cooking Oil. Best Oil heating.
Thermal Oil Heat Exchanger transfers heat efficiently. Very low
energy cost. Adjust and maintain the temperature of the Cooking
Oil. Increased Cooking Oil Shelf life because first, they heat the
Thermal Oil then it heated the Cooking Oil is Coal, Firewood and
Natural gas models are available.
3.5 Process Flow Line
Flow Chart
Proportion system
(optional)
Raw material
receiving system
Cutting system
Frying/Baking system
Raw
Material
Storage
Milling system
Conveying system
Extrusion system
Cooling system
Packing system
Mixing
Packing
Extrusion
Frying
Seasoning
Store
Nimko Flow Line
11
3.6 Quality Assurance and Quality Control Lab
3.6.1 Quality Assurance Lab
SM Food Makers has an established department known as the “Quality Assurance Department”
to check & assure the quality of raw materials including packaging materials.
Equipment to Protect Against Scalds and Burns Includes:




Heat-insulating gloves that provide complete coverage of hands and forearms.
Lab Coat.
Hair Cap.
Closed-toe footwear.
Good Manufacturing Practises (GMPS)
1. Quality Management
Quality management is a principle that focuses on ensuring that manufactured products are fit for
their intended use. For food, this means ensuring that the food meets the FDA's food safety and quality
measures. So, there should be no raw, expired, or improperly processed products that can potentially
harm consumers or cause contamination.
2. Sanitation and Hygiene
In terms of Good Manufacturing Practises, there is nothing more vital than sanitation and hygiene,
particularly for drug, cosmetic, and food manufacturers. This covers anything that can lead to
contamination if proper hygiene and sanitation are not practised. One step a facility can take to ensure
proper sanitation and hygiene is to install a food-grade stainless Slot Drain drainage system.
3. Suitable Facility Locations
The FDA's Current Good Manufacturing Practises state that manufacturing facilities should be in a
suitable location, free from the risk of contamination. Additionally, the facility should be designed to
help minimize the risk of potential errors in operations and should be easy to clean and maintain.
4. Equipment
Similar to the location requirements, any equipment within the facility should be designed, located,
and maintained to function as intended. All equipment should also be regularly cleaned and stored
according to the proper procedures, and removed if found defective or malfunctioning. Food processing
equipment is meant to streamline food processing and make it less labour-intensive. The equipment food
needs can be customized for homeowners or large-scale businesses in the food industry.
5. Raw Materials
Any materials for production are required to be stored appropriately. Furthermore, a proper inventory
of the raw materials‚ the facility has in stock‚ should be available and updated regularly, as well as
documentation of where the materials come from, to ensure quality.
6. Personnel
Naturally, successful GMP compliance relies heavily on facility personnel. Everyone who works for
the facility should be well-trained and qualified to do their assigned job. They should have a clear
awareness of the various GMP principles and receive continual training, so they are always up-to-date
with their job skills and what is expected by the FDA.
7. Validation and Qualification
12
The critical steps of the manufacturing process should be validated to ensure they meet specific GMP
qualification guidelines. Regular reviews of this process will also help to ensure that product quality
remains high and consistent.
8. Handle Complaints
Another key factor of Good Manufacturing Practises includes handling complaints. All companies
and facilities should have a GMP-compliant system for handling complaints. The ideal complaint system
should include prepared solutions for all contingencies within the facility.
9. Documentation and Recordkeeping
Keeping thorough records is an essential part of any company, and therefore a critical part of the
GMP. Everything about the facility should be documented in clear, legible ways. All documents should
be kept in an organized system where managers can easily find and refer to various aspects of the facility
at any time.
10. Inspections and Quality Audits
Another step that goes into Good Manufacturing Practises in all facilities is inspections and quality
audits. By regularly conducting inspections and audits, facilities can ensure that they are properly
complying with the GMP. These checks will also help to keep the facility from forgetting to follow the
guidelines; otherwise, they will be hit with serious consequences.
Lab Instruments
i. Titration Apparatus
Acid-base titrations are used to determine the concentration of a a sample of acid
or base and are carried out using a piece of equipment called a burette. It is a long,
glass tube with a tap at the end which can be used to very carefully add drops of
liquid to a test solution.
ii.
Refractometer
Refractometers are used in a variety of applications: From the determination of the purity
and concentration of ingredients of medications to the measurement of the sugar content
of food and beverages and the analysis of petroleum oil. The dilution of sunflower oil
with cheap oils can also be detected with this device.
iii. Weigh Scale
The weighing scale has two major variants, mechanical and digital weighing scales.
The mechanical scale features a rotating dial which indicates the weigh.
iv.
PH Meter
They are used to analyze the exact pH value of food grade products and chemical
products to ensure safety and quality, or they can be used to evaluate the
acidity/alkalinity of drugs in pharmaceutical and biotechnology industries.
v.
TDS Meter
A TDS meter is a small hand-held device used to indicate the Total Dissolved Solids
in a solution, usually water. Since dissolved ionized solids, such as salts and minerals,
increase the conductivity of a solution, a TDS meter measures the conductivity of the
solution and estimates the TDS from that reading.
13
vi.
Moisture Meter
Moisture meters are used to measure the percentage of water in a given substance. This
information can be used to determine if the material is ready for use, unexpectedly wet
or dry, or otherwise in need of further inspection. Wood and paper products are very
sensitive to their moisture content.
vii.
Sanitizer
Sanitizer is a product for cleaning something so that there are no germs or bacteria on
it. To sanitize means to clean something by removing the dirt or destroying the germs
on it. Food service operations use sanitizer to clean their equipment so that food doesn’t
become contaminated with bacteria or other stuff that shouldn’t be in it.
viii. Calculator
Basic calculators can do only addition, subtraction, multiplication and division
mathematical calculations. However, more sophisticated calculators can handle
exponential operations, square roots, logarithms, trigonometric functions and hyperbolic
functions.
ix.
Testo Meter
The digital cooking oil tester tests the quality of deep fry oil and measures total polar
material or total polar compounds.
x. Hot Plate
Hot plates are frequently used in the laboratory to perform chemical reactions, heat a
samples, and numerous other activities. Hot plates are conceptually simple – a flat
surface with heating elements. They do not produce open flames and are well suited for
oil or sand bath use.
3.7 Determination of Free Fatty Acids
Purpose:
To find out the free fatty acids present in frying oil.
Apparatus:



Weighing balance.
Conical flask.
Burette.
Reagents:



Sodium hydroxide – 0.1N.
Phenolphthalein indicator – 1.0%.
Ethanol.
Procedure:
1.
2.
3.
4.
The a sample must be well mixed and entirely liquid before weighing.
Take a 05 ml oil a sample in a conical flask.
Add 30 ml of neutralized ethanol and a few drops of phenolphthalein of indicator.
Titrate with alkali shaking vigorously to the appearance of the first permanent colour of the same
intensity as that of neutralized alcohol before the addition of the a sample.
5. The colour must be persisting for 30 seconds until light pink colour is obtained.
14
Calculation:
By the following formula
FFA% = MW/10 x BR/Wt. of a sample
BR
= Volume of NAOH used
N
= Normality of NAOH
Wt.
= Weigh of A sample
MW
= Molecular weigh of fatty acid.
Oleic Acid = 28.2 gms
3.8 Moisture of Product A sample
Purpose:
To find out the water contents in a a sample.
Apparatus:
Moisture Meter
Procedure:
1.
2.
3.
4.
5.
Cut the a sample of about 3-5g.
Turn ON the analyzer.
Put the a sample into it.
Set it at 100ºC.
Start up the analyzer after some time the percentage of moisture will be shown on the digital
meter.
6. If the moisture is under the specification, it will accept and release to the production otherwise
rejected and send back to the manufacture.
3.9 Moisture Determination by Using Hot Air Oven (Manually)
Purpose:
To find out the water contents in a a sample.
Apparatus:
1. Weighing Balance
2. Hot Air Oven
3. Desiccator
Procedure:
1.
2.
3.
4.
5.
6.
Grinding the a sample
Now take an empty petri dish and weigh it.
And put a sample (5g) in a petri dish and again Weigh it.
Now cool the petri dish in a desiccator.
Now at the end put it in Hot Air Oven for 2 hours, at 110 Degree Temperature.
After the time calculate the moisture by Formula :
15
3.10 Determination of FAT content in A sample (BEST NIMKO)
Material Required:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flat bottom flask
Solvent apparatus
Solvent extraction thimble
A sample (5g)
Chemical > n-Hexane (C6H40 ) 200ml
Beaker (200ml)
Hot air oven
Desiccator
Weighing Balance
Procedure:
1.
2.
3.
4.
First of all weigh an empty flat bottom flask.
Now put a sample in the solvent extraction thimble and weigh it.
Now take 200ml n-Hexane in a beaker and then put it in flat bottom flask.
Now set the flat bottom flask in the solvent apparatus and set the solvent extraction thimble in
extractor part of solvent apparatus.
5. Now heat a sample by heating mental at 69* for almost 3 hours.
6. After heating all the chemical moves to the extractor and the fat content extracted in the flat
bottom flask.
7. After 3 hours remove both the solvent extraction thimble and n-hexane from the extractor and
waste it.
8. Now again heat the flat bottom flask to remove if further n-hexane present in it.
9. Now put the flat bottom flask in Hot Air Oven for 1 hour and then put it desiccator to cool.
10. After cooling the flask now weigh it and calculate the fat content in a sample by the given
formula.
Observation:
Weigh of empty flask: 111.92g
Weigh of flask with the sample: 5.03g
Fat weigh: 113.14g
16
Formula:
=
𝐅𝐚𝐭 𝐰𝐞𝐢𝐠𝐡𝐭 – 𝐞𝐦𝐩𝐭𝐡𝐲 𝐟𝐥𝐚𝐭 𝐰𝐞𝐢𝐠𝐡𝐭
%
𝐒𝐚𝐦𝐩𝐥𝐞 𝐰𝐞𝐢𝐠𝐡𝐭
113.14−111.92
=
5
∗ 100
FAT % = 24.2 %
3.11 Determination of Free Fatty Acid in Palm oil
It is done to check the amount of free fatty acid in oil.
Materials Required:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Conical flask (100ml)
Chemical Ethanol (Absolute)
Phenolphthalein indicator (few drops)
NAOH
A sample > palm oil (5g)
Hot plate
Beaker
Burette
Weighing balance
Procedure:
1.
2.
3.
4.
First of all take chemical ethanol in 100ml flask.
Wight 5g a sample (palm Oil) in the flask by using weighing balance.
Now put flask at hot plate to mix it well.
Add few drops of phenolphthalein indicator, if it gives pink colour, it indicates the purity of
chemical.
5. Now titrate the solution with NaOH.
6. Note the burette reading until the presence of pink colour in solution.
7. Now calculate the amount of free fatty acid by the given formula.
Observation:
Burette reading = 1
A sample weigh = 5.03g
17
Formula:
𝑭𝑭𝑨% =
𝐁𝐮𝐫𝐞𝐭𝐭𝐞 𝐫𝐞𝐚𝐝𝐢𝐧𝐠 ×𝟎.𝟏 𝐍 𝐍𝐀𝐎𝐇×𝟐𝟖.𝟐
𝐒𝐚𝐦𝐩𝐥𝐞 𝐰𝐞𝐢𝐠𝐡𝐭
=
1.0 ×0.1 𝑁 ×28.2
5.03
%
∗ 100
FFA = 0.56 %
3.12 TDS TEST:
Total dissolved solids
RO water is used (distilled water).
If TDS is low water is good.
APPRATUS:
1. Beaker
2. Distilled water
3. TDS meter
PROCEDURE:
1. Take 100ml RO water in beaker.
2. Then put TDS meter in it and note the reading.
3. 0.21 Pipette reading is shown now convert the pipette into ppm then divide 0.21×1000.
TDS=210 ppm
3.13 Test to find PH
APPRATUS:
1. PH strip
2. Distilled water
PROCEDURE:
1.
2.
3.
4.
5.
6.
Dip pH strip in water.
The PH will be 6.6.
Water consists of H+ and OH- ions H+ ions show that it is acidic and OH- ions show it is basic.
Water is neutral with PH 7.
Then add phenolphthalein for indication if it shows pink colour it will be basic.
If it is colourless it will be acidic.
18
3.14 RANCIDITY TEST:
APPRATUS:
1.
2.
3.
4.
Cylinder
Palm oil
Concentrated HCL
Phloroglucinol solution
PROCEDURE:
1.
2.
3.
4.
5.
Take 25 ml of cylinder with stopped.
Add 5ml of a sample of oil in cylinder.
Then add 5ml of HCL in the cylinder and shake it.
Then add 5ml of phloroglucinol solution then shake it again.
Then hold beaker for 5 minutes to check the presence of oil that it show pink colour or it is
transparent.
6. If it show pink colour oil is rancid report will be shown positive.
7. If it is colourless oil is not rancid and report is shown negative.
3.15 GLUTIN TEST
PURPOSE:
To check elasticity of biscuits.
APPRATUS:
1.
2.
3.
4.
5.
6.
7.
8.
Refined wheat flour
Water
Sucker
Bowl
Weigh scale
Petri dish
Desiccator
Hot air oven
PROCEDURE:
1.
2.
3.
4.
5.
6.
7.
8.
Take 10g of a sample on weigh scale.
Then add 5ml of water in it for making dough through sucker.
Mix it well and dough is formed.
Then put dough in water for 15 mint to remove starch this process is known as washing.
Then put it under tap water and starch is removed.
As the starch is removed the dough colour is changed from white to brown.
Then take weigh of empty petri dish which is 42.0119g.
Then make small balls of dough and place the petri dish in hot air oven for 2 hours at 133c°
temperature.
9. Then take it out and put it in desiccator.
19
FORMULA:
=
𝐃𝐢𝐬𝐡 + 𝐆𝐥𝐮𝐭𝐞𝐧 𝐰𝐞𝐢𝐠𝐡𝐭 – 𝐞𝐦𝐩𝐭𝐡𝐲 𝐝𝐢𝐬𝐡 𝐰𝐞𝐢𝐠𝐡𝐭
%
𝐒𝐚𝐦𝐩𝐥𝐞 𝐰𝐞𝐢𝐠𝐡𝐭
= 𝟒𝟗. 𝟏𝟎𝟐𝟎 − 𝟒𝟓. 𝟎𝟒𝟕𝟓%
25.0502
Gluten = 16.18%
20
Chapter 4
RESULT & DISCUSSION
4.1 SENSORY EVALUATION OF PRODUCTS
A scientific discipline that applies principles of experimental design and statistical analysis to
the use of human senses (sight, smell, taste, touch, and hearing) to evaluate consumer products is
called sensory evaluation.
Table 4.1: Hedonic Scale
Sr. No.
GRADE
SCORE
1
Like extremely
9
2
Like very much
8
3
Like moderately
7
4
Like slightly
6
5
Neither like nor dislike
5
6
Dislike slightly
4
7
Dislike moderately
3
8
Dislike very much
2
9
Dislike extremely
1
21
4.1.1 Biscuits
The sensory quality of biscuits can be evaluated by affective (subjective) methods such as
consumers’ acceptance tests and by analytical (objective) methods Sensory evaluation with hedonic
scale parameters are:
Table 4.1.1: Sensory Evaluation of Biscuits
R1
R2
R3
Sr. No.
Parameter
Mean ± S. D
1
Appearance
8.0
7.0
8.0
7.7 ± 0.6
2
Colour
8.0
6.0
7.0
7.0 ± 1.0
3
Texture
7.0
7.0
8.0
7.3 ± 0.6
4
Taste
8.0
7.0
7.0
7.3 ± 0.6
5
Aroma
7.0
7.0
8.0
7.3 ± 0.6
6
After Taste
7.0
8.0
6.0
7.0 ± 1.0
7
Overall acceptability
7.0
8.0
7.0
7.3 ± 0.6
9
7.7
8
7
7
6.3
7
7.3
7
6.3
6
5
4
3
2
1
0
Appearance
Color
Texture
Taste
Aroma
Fig 4.1.1: Sensory Evaluation of Biscuits
22
After Taste
Overall
acceptability
4.1.2 Nimko
Many efforts have been made to improve the quality and stability of Nimko because consumer demand
for healthy fast food has increased rapidly in recent years. Olive oil is the most mono-unsaturated
vegetable oil. It contains ~50% palmitic acid, 40% oleic acid, and 10% linoleic acid.
Sr. No.
Table 4.1.2: Sensory Evaluation of Nimko
R1
R2
R3
Parameter
Mean ± S. D
1
Appearance
7.0
6.0
8.0
7.3 ± 1.0
2
Colour
6.0
8.0
6.0
6.7 ± 0.6
3
Texture
7.0
6.0
6.0
6.3 ± 0.6
4
Taste
7.0
6.0
7.0
6.7 ± 0.6
5
Aroma
8.0
7.0
6.0
7.0 ± 1.0
6
After Taste
7.0
8.0
7.0
7.3 ± 0.6
7
Overall acceptability
7.0
8.0
6.0
7.0 ± 1.0
9
7.7
8
7
7
6.3
7
7.3
7
6.3
6
5
4
3
2
1
0
Appearance
Color
Texture
Taste
Aroma
Fig4.1.2: Sensory Evaluation of Nimko
23
After Taste
Overall
acceptability
4.2 PERSONAL HYGIENE
4.2.1 Personal Hygiene Data of Day 1
The Data of personal hygiene has been evaluated for four days. The data of the first day is
presented in Table 4.2.
Table 4.2.1 Personal Hygiene Data of Day 1
Sr. No
Frying Section
Face Mask
Hygiene Cap
Gloves
Uniform
Remarks
1
Labourer 1
No
No
No
Yes
Fail
2
Labourer 2
Yes
Yes
Yes
Yes
Pass
3
Labourer 3
Yes
Yes
No
Yes
Pass
4
Labourer 4
Yes
Yes
Yes
Yes
Pass
5
Labourer 5
No
No
No
No
Fail
We visited frying section to check the personal hygiene of food handlers and workers. We
checked 5 labourers in a week in which 3 labourers passed because they were wearing hygiene gear. 2
Labourer failed the personal hygiene test because they were not wearing hygiene gear while working in
the frying section. Improvement notices and a warning notice was served to frying section in charge.
These visits were not planned visit and it is called sudden visit.
4.2.2 Personal Hygiene Data of Week (Day 2)
The data of personal hygiene for the second day is presented in Table 4.2.
Table 4.2.2 Personal Hygiene Data of Day 2
Sr. No
Extrusion Section
Face Mask
Hygiene Cap
Gloves
Uniform
Remarks
1
Labourer 1
Yes
Yes
Yes
Yes
Pass
2
Labourer 2
Yes
Yes
Yes
Yes
Pass
3
Labourer 3
Yes
Yes
Yes
Yes
Pass
4
Labourer 4
Yes
No
No
Yes
Fail
5
Labourer 5
Yes
Yes
Yes
Yes
Pass
A total 5 labourer were monitored during the second day. We visited Extrusion Section to check the
personal hygiene of handlers and workers. We check 5 labourers in which 4 labourers were passed
because they were wearing hygiene gears. 1 labourer failed the personal hygiene test because he was not
wearing hygiene gear while working. Improvement notices and a warning notice was served to Extrusion
section in charge. It was also a sudden visit.
24
4.2.3Personal Hygiene Data of Day 3
The data of personal hygiene for the third day is presented in Table 4.2.3.
Table 4.2.3 Personal Hygiene Data of Day 3
Sr. No
Packaging Section
Face Mask
Hygiene Cap
Gloves
Uniform
Remarks
1
Labourer 1
No
No
No
Yes
Fail
2
Labourer 2
Yes
Yes
Yes
Yes
Pass
3
Labourer 3
Yes
No
Yes
Yes
Pass
4
Labourer 4
No
Yes
Yes
Yes
Pass
5
Labourer 5
Yes
Yes
Yes
No
Pass
A total 5 labourer were monitored during the day 3. We visited Packaging section to check the
personal hygiene of food handlers and workers. We checked 5 labourers in which 4 were passed because
they were wearing hygiene gear. And the environment was good and clean. And 1 labourer failed the
personal hygiene test because she was not wearing hygiene gear while working. Improvement notices
and a warning notice was served to packaging section in-charge.
4.2.4 Personal Hygiene Data of Day 4
The data of personal hygiene for the day 4 is presented in Table 4.2.4.
Table 4.2.4 Personal Hygiene Data of Day 4
Sr. No
Kitchen
Face Mask
Hygiene Cap
Gloves
Apron
Remarks
1
Labourer 1
Yes
No
Yes
Yes
Pass
2
Labourer 2
Yes
Yes
Yes
Yes
Pass
3
Labourer 3
No
No
No
No
Fail
4
Labourer 4
Yes
Yes
Yes
No
Pass
5
Labourer 5
No
Yes
Yes
Yes
Pass
A total 5 labourer were monitored during the day 4. We visited Kitchen to check the personal
hygiene of food handlers and workers. We checked 5 labourers in which 4 labourers were passed because
they were wearing hygiene gear. And the environment of the store room, and kitchen was quite good
and clean. 1 labourer failed the personal hygiene test because he was not wearing hygiene gear while
working in the kitchen. Improvement notices and a warning notice was served to this labourer.
25
4.2.5 Personal Hygiene Data of Four Days
The data of personal hygiene for the four Days is presented in Table 4.4.
Table 4.4 Personal Hygiene Data of Four Days
Day 1
Day 2
Day 3
Day 4
Pass
3
4
4
4
Fail
2
1
1
1
A total 4 sections and 20 labours were monitored during the four days. We visited 4 sections to
check the personal hygiene of food handlers and workers. We monitored 20 labourers in a day in which
15 labourers were passed because the workers and food handlers of these sections were wearing hygiene
gear. And the environment of the store room, and kitchen was quite good and clean. 5 labourer failed the
personal hygiene test because the workers and food handlers were not wearing hygiene gear while
working. Improvement notices and a warning notice was served to section in-charge. These visits were
not planned visits and these are called sudden visits.
26
CHAPTER 5
OUTCOME AND CONCLUSIONS
In the review, this internship has been an excellent and rewarding experience. We have been able
to meet and network with so many people that we are sure will be able to help with opportunities in the
future. One main thing that we have learned through this internship is time management skills as well
as self- motivation. When we first started, we didn’t think that we were going to be able to make
ourselves work for this industry for 2-4 hours a day, five days a week. Once we realized what we had to
do we organized our day and work so that we were not overlapping or wasting our hours. We learned
that we need to be organized and have questions ready for when it was the correct time to get feedback.
From this internship and time management, we had to learn how to motivate ourselves through being in
the industry for so many hours. We came up with various proposals and ideas that the company is still
looking into using. We learned very much during this period we met so many wonderful people and
professionals who guided us through this internship period. Here we learned and saw practical
application and implementation of theoretical knowledge of food science and technology and completed
our projects which were assigned to us by our external supervisor Mr. Umar Daraz (Deputy Manager
Quality), Mr. Syed Raheel Abbas Kazmi (Food Security Officer) and Mr. Muhammad Kashif
(Labouratory Officer)
We have learned a lot and developed our skills in the following:
1. Raw material checking (Oil, seasoning, cartons, etc.).
2. Biscuit and Nimko processing line.
3. Functions of Biscuit and Nimko ingredients.
4. Determination of quality defects in Biscuits and Nimko.
5. Food safety system management.
6. Worker safety and hygiene management.
7. Halal control point management.
8. Insects’ pest management.
9. Audit techniques for the food industry.
10. Learn how to audit the food industry.
11. Recommendations to reduce eliminate and minimized quality defects.
12. Recommendations about food safety and hygiene.
5.1 What we have learned in formal and informal ways?
5.1.1 Time Management:
As Quality Control Officers, we have always to run against a tight timeline and packed schedule
to assure the quality of the production target. It taught us the importance of time management and
develops some skills in ourselves to meet close deadlines.
I. Goal Management:
According to the guidance of our senior, we divided our goals into small steps and are usually
able to manage them well.
II. Colleague Interactions:
Our internship taught us teamwork. Our entire colleagues paid great respect to each other and
divergent creative ideas. We worked with them as a team. We came to know the importance of teamwork.
We would like to once again appreciate everyone who has made our industrial training.
27
III. General Remarks:
The internship at SM Food Makers was a great opportunity to learn new things and exposure to
professional life. Our self-confidence has been enhanced. We learned how to work in professional life.
28
REFERENCES
Sietsema, Robert (January 27, 2009). "Strange Snacks of the World -- Cracker Nuts". Village Voice.
Retrieved September 1, 2016.
Erdogan, Hula (June 1999). "High moisture food extrusion". International Journal of Food Science &
Technology (Submitted manuscript). 34 (3): 195–207. Doi:10.1046/j.1365-2621.1999. 00256. x.
Guy, Robin (2001). Extrusion Cooking: Technologies and Applications. Cambridge: Wood head
publishing.
"Rotary Head Extruder". American Extrusion. 17 October 2017. Retrieved 17 October 2017.
Riaz, Mian N. (2000). Extruders in Food Applications. CRC Press. p. 193. ISBN 9781566767798.
R.C.E Guy, “Extrusion Technologies” in Reference Module in Food Science, 2016.
M.N. Riaz, “Snack Food, Processing “in Reference Module in Food Science, 2016.
M.N. Riaz, "GRAIN-BASED PRODUCTS AND THEIR PROCESSING" in Encyclopedia of Food
Grains (Second Edition), 2016.
Food processing, EPa. "How to Make Sweet and Salted Banana Chips". Archived from the original on
28 December 2011. Retrieved 16 May 2012.
Dalsass, Diana (15 March 1999). New Chocolate Classics: Over 100 of Your Favorite Recipes Now
Irresistibly in Chocolate. W. W. Norton & Company. p. 36. Retrieved 15 March 2018 – via Internet
Archive. Chocolate Rugelach.
Burtea, O (2001). "Snack Foods from Formers and High-Shear Extruders". In Lusas EW; Rooney LW
(eds.). Snack Foods Processing. p. 287. ISBN 1-56676-932-9.
Tull, Anita (2012). Food Technology: An Introduction. Oxford University Press. Pages 40–
41. ISBN 0198328192.
Lusas, Edmund W. Lusas; Rooney, Lloyd W. (editors) (2001). Snack Foods Processing CRC
Press. ISBN 1420012541.
Reineccius, Gary (2005). Flavour Chemistry and Technology, Second Edition. CRC Press. p
405. ISBN 0203485343.
Snack Food Technology—Samuel A. Matz—Google Books. (n.d.). Retrieved December 5, 2022, from
https://books.google.com.pk/books.
Extrusion Processes—ScienceDirect. (n.d.). Retrieved December 19, 2022, froom https ://www.
sciencedirect.com/science/article
Ciurzyńska, A., Cieśluk, P., Barwińska, M., Marczak, W., Ordyniak, A., Lenart, A. and Janowicz, M.,
2019. Eating habits and sustainable food production in the development of innovative “healthy”
snacks. Sustainability, 11(10), p.2800.
Katz, E.E. and Labuza, T.P., 1981. Effect of water activity on the sensory crispness and mechanical
deformation of snack food products. Journal of Food Science, 46(2), pp.403-409.
Booth, R.G. ed., 1990. Snack food. Springer Science & Business Media.
Duizer, L.M., Campanella, O.H. and Barnes, G.R.G., 1998. Sensory, instrumental and acoustic
characteristics of extruded snack food products. Journal of texture studies, 29(4), pp.397-411.
Matz, S.A., 2012. Snack food technology. Springer Science & Business Media.
YAĞCI, S. and GÖĞÜŞ, F., 2009. Development of extruded snack from food by‐products: a response
surface analysis. Journal of Food Process Engineering, 32(4), pp.565-586.
29