Parle Biscuits Private Limited (PBPL), Khopoli
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6 September 2018 - 17:05, by , in blog, ITM Institute, PGDM, Comments off

Kautilya Batch 2018-2020 (PGDM Operations And SCM &IT and Analytics) went for industrial visit organized on 25th Aug’18, Saturday. 63 students along with 4 professors, Prof. Kalpana Kumaran, Prof. Yogita Rawat, Prof. Pushpendu Rakshit and Prof Gayatri Kapale accompanied went for the visit. Upon reaching the site, the Parle Team welcomed us and briefed us about the company and also showed one animated video which contained all the details of the processes in bits and pieces.

To begin with, Parle has been India’s leading manufacturer of biscuits and confectionery and known for its major products like Parle-G, POPINS, Hide N Seek, Monaco, Milano etc. It was quite astonishing to see the factory which had started with just 12 people making confectionery now has 750 people making them. Parle has come a long way since its launch in year 1928 by Mohanlal Dalal, has now gained accepted not only in Indian markets but also International Markets as well.


Production Capacity: –
Production capacity depends upon availability of raw materials as well as the number of labor workforce. The Total Production Capacity of the factory is 250-metric tons. Within that Parle-G constitutes 50-metric ton, another 50-metric ton for candy, 35-metric tons for Hide N Seek, 35-metric tons for Cheezos and remaining 110 metric tons for others.


Facts: –

  • Apart from the original factory in Mumbai, Parle has manufacturing facilities at Neemrana (Rajasthan), Bangalore (Karnataka), Kutch (Gujarat), Khopoli (Maharashtra), Pantnagar (Uttarakhand), Sitarganj (Uttarakhand) and Bahadurgarh (Haryana).
  • Bahadurgarh (Haryana) and Pantnagar (Uttarakhand) plant are one of the largest manufacturing plants of Parle in India. It deploys large scale automation for manufacturing of quality biscuits. It also has several manufacturing units on contract.
  • Since they have been entered at the food competition of Monde Selection in 1971, the brands have received consistently gold and silver Quality Awards at the World Quality Selections.
    Parle has acquired the Asia’s Largest Oven.
  • Can extend the Total Production Capacity to produce an extra 50-55 metric tons.
  • Biscuits which are burnt, spoiled or broken are manually removed through segregation.
  • Broken biscuits are re-used whereas spoiled biscuits are sent for cattle-feeding.
  • Production quantity is classified into 70 grams small biscuit packets, 120 grams big biscuits packets, 80 grams packets to be sent to CSD (Canteen Stores Department, is a solely owned Government of India Enterprise under Ministry of Defense and has its depot in all major military bases operated by the Indian Armed Forces).
  • Product Layout Pattern is being followed in Parle.

Automation :-
It was observed during the visit that most of the processes were automated and managed with the help of control systems for operating equipment such as machinery, processes in factories, boilers and heat treating ovens etc. In the simplest type of an automatic control loop, a controller compares a measured value of a process with a desired set value, and processes the resulting error signal to change some input to the process, in such a way that the process stays at its set point despite disturbances. Computers can perform both sequential control and feedback control, and typically a single computer will do both in an industrial application. Programmable logic controllers (PLCs) are a type of special purpose microprocessor that replaced many hardware components such as timers and drum sequencers used in relay logic type systems. General purpose process control computers have increasingly replaced stand alone controllers, with a single computer able to perform the operations of hundreds of controllers.


Operations:-
As known earlier Parle manufactures many sub-brands in confectionery section. Hence, there are different layout patterns, production capacity per day and process involved.

1) Parle-G: – The manufacturing process of the Parle-G biscuit goes through a series of steps they are follows:

  • a) Raw material testing: – Biscuits are made out of mixture of wheat, milk and edible oils which serve as the raw materials. These raw materials undergo vigorous testing process due to the quantity of biscuits produced are in bulk. Hence, there should be no room for error in this primary stage of production.
  • b) Mixing: – Raw materials after undergoing testing process are mixed to together to form a mixture.
  • c) Forming: – The mixture is moved to forming machine where the mixture is formed/shaped properly. The movement of materials is automated through the usage of conveyor belts.
  • d) Packing: – This process is done manually through the use of unskilled labor where the biscuits are tightly packed in poly-bags and set into cartons. 1 poly-bag accommodates 24 biscuit packs whereas a single carton accommodates 6 poly-bags.

Parle Toffee: –

  • a) The Milk Tank supplies milk which is used along with edible oil to produce a mixture.
  • b) The Mixture is formed into a toffee shape then send over to Toffee cooker.
  • c) Toffee cooker is the place where the flavors are added to the toffee.
  • d) After flavors added the toffees are send over to the cooling machine where they are preserved and maintained.
  • e) The Final step is packaging where the toffees are packed and transported to markets.

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