Gourmet Foodsali

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    INTRODUCTION OF GOURMET FOODS

    In 1987 Gourmet Foods is a family ownedpartnership business started by Mr. Muhammad

    Nawaz Chattha

    1st July, 2008 his sons joined him in the business

    Business set up is based in Lahore

    98 sales outlets in runningposition supported by 5 units

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    MISSION STATEMENT

    Gourmet with an aim to make

    Delicious

    Hygienic

    Healthy food

    That contributes to positive health

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    MILK PROCESSING IN

    GOURMET FOODS

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    COLLECTION OF RAW MILK

    Raw milk received

    The farmers

    Collectors from the collecting areas of the industry

    Transported

    Transported to the milk processing plant

    Chilled at a constant temperature (40C) after being pumpedinto a storage tank for any length of time

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    MILK RECEPTION

    Tanker enters into the Gourmet foods, sample is taken by Labtechnician. ThenLab Technicians perform the tests needed

    Then tanker comes to the receiving area where finally the

    reception of the milk takes place by the centrifugal pumps

    Milkcomes into storage tank thengoes to clarifier

    Milkgoes toward the PHE where its Chilled

    and stored into the big silos

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    RECEPTION LAB

    The composition of milk and adulteration in milk is usuallydetermined by a number of tests on arrival at the dairy &

    adulterated milk is not accepted

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    STORAGE OF MILK

    After the completion of the reception tests, the tankers are

    accepted or rejected if accepted then

    Milk from accepted tankers receive in receiving lines

    From receiving lines, milkcomes in silos

    There are six silos in Gourmet Foods unit 3

    Capacity of 2 silos are25000 liters

    Capacity of 2 silos are15000 liters

    Capacity of 2 silos are 10000 liters

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    TEST CARRIED OUT TO CHECK

    THE QUALITY OF MILK

    All the quality tests are carried out at the time of arrival of

    milk in the dairy plant in the reception lab.

    In reception lab 4 types of tests are performed which are givenbelow.

    Physical tests

    Qualitative tests

    Quantitative tests

    Adulteration tests

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    PHYSICAL TESTS

    Taste

    Check taste of milk. It should not give odd taste

    Smell

    Take in the aroma of milk. It should be of milky odour

    AppearanceMilk should be of uniform color and texture

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    QUALITATIVE TESTS

    Five qualitative tests are performed for raw milk

    1. Check temperature of milk

    2. pH

    3. Clot on boiling test (COB)

    4. Alcohol precipitation test (APT)

    5. Determination of Acidity

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    QUANTITATIVE TESTS

    In Gourmet foods Four types of quantitative tests are performed .

    1. Determination of Fat in Milk

    2. Lactometer Reading (28)

    3. Solids not fat (SNF )

    4. Total solids (TS)

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    ADULTERATION TESTS

    In Gourmet foods four types of adulteration tests are performed

    1. Detection of Detergent in Milk

    2. Detection of Starch in Milk

    3. Detection of Glucose in Milk

    4. Detection of Sugar (Sucrose) in Milk

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    PASTEURIZATION OF MILK IN

    GOURMET FOODS Milk Silo

    Balance tank

    Regeneration Section (44-45oC)

    Separator

    Homogenizer (100-150 bar)

    Heating Section (80-85oC)

    Holding Tubes (15 Sec)

    Regeneration Section (55-60o

    C) Cooling Section (7-8oC)

    Packing of milk (litter pack)

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    POWDER PLANT

    Milk powder is the product obtained by the removal of water

    from milk by heat

    Spray dryer is used for drying and falling film evaporator is

    used for the evaporation

    The capacity of the powder plant is 24bags in1 hours of

    durationconsisting each bag with 25 kg of dry milk powder

    Reception and pasteurization of milk is done at unit 3 then

    send it to unit 5 for the production of powder milk

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    MANUFACTURING OF POWDER MILK IN

    GOURMET FOODS

    Milk silo

    Balance tank

    Standardization Pasteurization

    Storage of milk into tanker

    Milk from unit 3 transfer to unit 5

    Evaporation (Brix 40-50)

    Spray dryer (remove water)

    Packing into bags

    Storage cold & dry place

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    GHEE

    It is desiccated butter

    Which have moisture content not more then 0.5 %

    Shelf life is up to one year

    Gourmet Foods produce its own desi ghee for the purpose of

    making sweets

    Gourmet desi ghee is not for sale

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    GOURMET DAIRY

    ICE CREAM

    It is frozen product which is obtained by the blending of fat,

    SNF, sugar, stabilizer, emulsifier incorporated with air when

    we freeze

    In Gourmet foods two kinds of mixes are produce for ice

    cream manufacturing Kulfa mix and plain mix.

    In Gourmet Foods 15 kinds of ice cream are manufacture

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    RAW MATERIAL FOR ICE CREAM

    1. Sugar

    2. Dry Skim Milk

    3. Fresh Cream

    4. Liquid Glucose

    5. Pulsgaurd

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    ICE CREAM MANUFACTURE

    The basic steps in the manufacturing of ice cream are generally asfollows

    Blending of the mix ingredients Pasteurization (80-85oC)

    Homogenization (100-150 bars)

    PHE (8oC)

    Aging the mix (4-6 hours)

    Freezing

    Packaging

    Hardening (-30 to -35oC for 24 hours)

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    KHOYA

    Khoya is concentrated whole milk product having moisture

    percentage 35%

    In Gourmet foods Khoya contain 35-40% fat

    After the manufacturing of khoya, it is packed

    Khoya is also not for sales

    Khoya is used for the preparation of sweets

    Some time khoya is used in the preparation of kulfa ice cream

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    PREPARATION OF KHOYA

    In Gourmet food stainless container with steam jacketed are used

    for the preparation of Khoya

    Take raw milk at 10-12oC in to pan

    Heat milk at 85-90oC for 30 minutes and stir

    Then addition of milk powder 3kg+3liter water at 65oC

    Thencooling at room temperature

    Then pack Khoya into 10kg polyethylene bag

    Shelf life is 5-8days at room temperature

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    PANEER

    Paneer is a product obtained by heating and acid coagulation of

    milk

    It should not contain moisture above then 70% and fat contain

    23-26 %

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    PREPARATION OF PANEER

    Raw Milk is come into paneer section temperature of milk is4oC

    Then boil the milk for1-2 minutes at 95oC and continuously

    agitate the milk

    Thencool the milk up to 70oC and continuously agitate the milk

    Citric acid is added in milk and curd is formed with in 5-6minutes

    Ageing is done for 8-10 minutes with slow agitation

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    Whey is drained off

    Washing of curd with water and whey+water is removed

    At this stage curd has not sour taste

    Separation ofcurd by the help ofcheese clothes by pressing

    the curd

    Mining of paneer is done

    Then pack and store at 4oC

    Paneer is used for the manufacturing of sweets

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    CLEANING IN PLACE

    Before any operation during milk processing anything must be

    clean

    Cleaning is carried out by circulating ofcleaning agent in

    processing line is called C.I.P

    In Gourmet foods C.I.P carried out by following steps

    1. Water rinsing for10 minutes

    2. NaoH rinsing for10 minutes3. Water rinsing for 5 minutes

    4. Nitric acid rinsing for10 minutes

    5. Water rinsing for 5 minutes

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    WATER SOFTENING PLANT

    In Gourmet foods 2 water softening plants are present

    Capacity of both plants are 4 tons

    Water softening by Na-zeolite

    Zeolite react with Ca+2, Mg+2 ions and convert into Ca, Mg

    Zeolite

    Limit of hardness is 60 ppm

    Zeolite should be changed after every year

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    BOILER

    In Gourmet foods 2 boiler are used for production of steam

    It is also called steam generator

    The temperature of steam is 180oC

    Boiler #1 Boiler #2

    Types Fire tube Fire tube

    Capacity 4 tons/hour 6tons/hour

    Working pressu

    re 250PSI 150PSITDS 3000-4000ppm 3000-4000ppm

    Company PIE PIE

    Modal PIE1011 PIE1016

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    Feed water pressure is 10-15 PSI high to boiler pressure

    Boiler efficiency depends upon feed water temperature

    To increase the temperature of feed water economizer is used

    Economizer is placed at the exhaust side of boiler

    Economizer increased the boiler efficiency 2-10 %

    Gas and furnace oil is used to operate the boiler

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    COMPRESSOR

    Gourmet foods three types ofcompressors are used

    1. Ammonia compressor2. Freoncompressor

    3. Aircompressor

    Power rang ofcompressors are 3-30 hp Hermetic type

    Not repairable

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    CONDENSER

    Gourmet foods 2 types ofcondensers are used

    1. Aircooled2. Shell and tube

    Condensers are local & German made

    Hermetic type Not repairable

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    FREEZER

    In Gourmet foods 12 freezers are used

    4 freezers are Italy made and 8 freezers are china made

    Power range of freezers are 10-15hp

    Two types of freezers are used in Gourmet foods

    Air blast freezer (storage)

    Continuous freezer (ice cream)

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    COOLING TOWERS

    Gourmet foods 4 cooling towers are used

    They are natural type

    Capacity of each cooling tower is 150 tons/hour

    When water enter incooling tower temperature is 35oC

    When water leaves cooling tower temperature is 27oC

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    GENERATOR

    Gourmet foods 2 generator are used for the production ofelectricity incause of emergency

    Generator # 1 Generator # 2

    Model P730P 800F

    Color Blue Yellow

    Made Ireland U.K Ireland U.K

    Power 730KVA 725KVA

    Company FG Wilson CAT

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