Survey of omeli pie production process at bao hung joint stock company

THAI NGUYEN UNIVERSITY OF AGRICULTURE AND FORESTRY THE ADVANCE EDUCATION PROGRAM BACHELOR THESIS TOPIC TITLE : SURVEY OF OMELIPIE PRODUCTION PROCESS AT BAO HUNG INTERNATIONAL JOINT STOCK COMPANY Full name : Pham Thao Linh Study Mode : Full time Major : Food Technology Faculty : Advance Education Program Batch : 2016-2020 Supervisor (s) : Dr Vu Thi Hanh THAI NGUYEN - 2020 i Thai Nguyen University of Agriculture and Forestry Degree Program Bachelor of Food Technology Student name Pham Thao Linh Student ID DTN1653050258 Thesis Title Survey of Omeli pie production process at Bao Hung joint stock company Supervisor Dr Vu Thi Hanh Abstract: Modern life, people spend a lot of time at work They will always pay attention to the quality of life, especially the nutritional value of products, especially foods such as confectionery Therefore, this survey aims to analyze and participate directly with the official QC position of the company The goal is to review the production process, analyze the hazards affecting products, learn and access practical knowledge from the factory This survey is conducted with modern systems, lines, and machines The method of implementation is monitoring, observing, learning, using, and collecting actual data on the parameters in the line and managing the quality of the product Line survey showed that some problems still existed on the production line Directly participating in the line QC detecting many physical, chemical, biological, and microbiological hazards directly related to the quality of the product Especially, Omeli pie product line is a pioneer in the company's brand lines Therefore, QC always monitors and monitors the process and handles all hazards to ensure product quality when it reaches consumers Key Words QC , Omeli pie Number of Pages 77pages Date of Submission August 30 , 2020 Supervisor’s signature ii LIST OF FIGURE Figure 2.1 : Omeli Cracker Gac FriutFigure 2.2: Break Sakago Figure 2.3 : Chew Candy 100 Fruit Figure 2.4 : Omeli Pie Matcha Figure 2.5 : Softcake Frome Figure 2.6 : Cream Egg Cookies Toplus .9 Figure 2.7: Danmark Pie Coconut .9 Figure 4.1 : Cooking cream process 31 Figure 4.2 : Mixing chocolate process 33 Figure 4.3 : 2-axis mill 36 Table 4.1: The table uses water quality criteria in the process .45 Figure 4.4: Cutting machine area 51 Figure 4.5 : Wire cutter .52 Figure 4.6 : Cake after baking 53 Figure 4.7: Put the cream in between the two layers 58 Figure 4.8 : Cake after covered chocolate .60 Figure 4.9 : Packaging machine 63 iii LIST OF TABLE Table 2.1: Table of test results of treated waste water 20 Table 2.2 : Property of ingredient in Omeli pie 21 Table 4.1 : The table uses water quality criteria in the process 45 Table 4.2 : Criteria and prperty of Omeli Pie 65 Table 4.3 : Product testing method 66 LIST OF ABBREVIATIONS QA : Quality Assurance QC : Quality Control ISO : The International Organization for Standardization iv TABLE OF CONTENT LIST OF FIGURE ii LIST OF TABLE iii TABLE OF CONTENT iv ACKNOWLEDGEMENT vi PART INTRODUCTION .1 1.1 Introduction 1.1.1 Nutritional value of Omeli pie 1.1.2 The convenience of the product 1.1.3 The domestic market 1.1.4 Purpose of inquiry and survey PART LITERATURE REVIEW 2.1 History of Bao Hung international joint stock company 2.1.1 Company introduct .4 2.1.2 History of formation and development 2.2 Omeli Pie chain ground diagram 2.3 Organizational structure, functions of members 2.4 The company's product lines 2.5 Industrial hygiene, labor safety and fire protection at the factory 10 2.6 Labor safety and fire prevention at the factory 14 2.7 Waste water treatment process 16 2.8 Materials 20 PART MATERIAL AND METHOD 27 3.1 Methods .27 3.1.1 Object (material) and scope of the study 27 3.1.2 Location and time of conducting research .27 3.1.3 Instrument 27 3.2 Content 27 3.3 Research methods 28 3.3.1 Practical investigation methods .28 v 3.3.2 Method of description 28 3.3.3 Methods of collecting information: 28 3.3.4 Methods of analyzing hazards 28 PART 4.RESULTS AND DISCUSSION 29 4.1 Product process Omeli Pie at Bao Hung company .29 4.2 Omeli process description 30 4.2.1 Prepare materials .30 4.2.2 Cooking cream 30 4.2.2.2 Whipping .32 4.2.3 Chocolate process technology 32 4.3 Survey process 38 4.3.1 Material 38 4.4 Explain the process of making Omeli Pie 46 4.4.1 The process of mixing .46 4.4.2 Shaping stage 50 4.4.3 Oven 53 4.4.4 Cool 57 4.4.5 Put the cream in between the two layers 58 4.4.7 Covered with chocolate 60 4.4.8 Cooling .61 4.4.9 Packaging I .63 4.4.10 Packaging II 64 4.4.11 Cool storage 64 4.4.12 Product quality criteria 65 4.4.13 Methods of product inspection and disposal of defective products .66 PART V CONCLUSIONS AND RECOMMENDATIONS .68 5.1 Comment 68 5.2 Request .68 5.3 Conclusion 68 REFERENCES 70 vi ACKNOWLEDGEMENT To complete my graduation report, in addition to my hard work, I also received the enthusiastic help of teachers and friends First of all, I would like to express my sincere thanks to Mr Pham Van Thuan - Deputy Technical Director of Bao Hung International Joint Stock Company - with all the officials and employees in the company for their dedicated help and favorable conditions for me to complete my graduation thesis I would like to express my gratitude to Dr Vu Thi Hanh - Lecturer of Faculty of Biotechnology and Food Technology - Thai Nguyen University of Agriculture and Forestry, dedicated and guided throughout the project I would like to express my thanks to the teachers and civil servants in the School of Biotechnology and Food Technology and all the teachers in Thai Nguyen University of Agriculture and Forestry, who taught and led guide me in my time at school So I would like to express my sincere thanks to my parent and friends for encouraging and helping in my study PART INTRODUCTION 1.1 Introduction 1.1.1 Nutritional value of Omeli pie Omeli pie is a type of cake that is very familiar to Vietnamese consumers and the world It has been loved by many people because it is both delicious, attractive and contains many nutrients Each cake has a very high nutritional value from ingredients such as milk, butter, cocoa, eggs, and other ingredients An Omeli pie is made up of two layers of chocolate-covered sponge cake put between a layer of greasy marshmallow cream According to research, an Omeli pie contains 120 calories, g fat, 18 g sugar, g protein, and 0.08 g fiber The amount of calories in an Omeli pie is almost equal to a bowl of rice (130 calories) At every meal, it is necessary to have protein supplements to provide energy for the body and to form, maintain, and replace cells in the body Protein is also important for growth and development during childhood, adolescence, and pregnancy Lack of protein will lead to malnutrition, growth retardation, immunodeficiency, adversely affecting the function of organs in the body Not only protein, but Omeli pie also adds minerals beneficial to the body such as iron, calcium Iron plays an important role in the production of hemoglobin - a substance in blood cells Iron deficiency is synonymous with anemia in the body Therefore, to avoid this situation, we can use Omeli pie to contribute iron supplements to the body So if you have not chosen a product that can provide enough energy, Omeli pie will be the best choice 1.1.2 The convenience of the product Modern life, people always spend most of their time at work Therefore, in recent years, people have always focused on convenient products that bring high nutritional value to each meal This is the reason that the food processing industry has developed strongly, contributing to meeting the needs of people Omeli pie is a kind of cake that brings a lot of convenience for people They have an eye-catching and compact design that is convenient for humans Omeli pie always provides, ensuring nutritional value for every meal Usability is instant food that helps people save time And in particular, they have the advantage of using time and preserving a longer time Omeli pie can be used as a breakfast for young children to save time for busy families Therefore, Omeli pie is a smart and convenient choice for life 1.1.3 The domestic market More than 20 years ago, when it comes to pie people would think of Pham Nguyen a big man in the soft cake industry Pham Nguyen Company is the first company to import more than million USD from Korea to produce a chocolatecovered soft cake In 2015, Pham Nguyen was the leader in the soft cake segment with sales of more than US $ 30 million, growing 15% per year compared to the industry growth of around 5% Pham Nguyen Confectionery's products have been sold at 120,000 retail outlets throughout Vietnam Today the market has many brands in the confectionery industry such as Trang An, Hai Ha, Bibica, Bao Hung Currently, many businesses invest in building modern production plants with modern lines like Korea , Germany and the UK up to millions of dollars 1.1.4 Production and consumption in the world Pie is a type of cake that was invented and produced in 1974 in Korea Initially, pie was created to provide troops for distribution to soldiers after the first week of train Pie is considered the quintessence of culinary culture of Korea It has been popular all over the world and its consumption is also very large With the creation of new flavors and convenient products is a step to promote the growing confectionery market Judging by the size of the market, the traditional flavored pie is the largest market share in the world The countries present in the range of pie products are Russia, China, South Korea and Japan In 2015, the country with the largest consumption of pie in the world was 1.3329 In Asia, Orion is currently the market leader in the pie industry domestically and globally in the case of both sales and sales volume Orion already accounts for two-thirds of China's pastry market, and chocopie were sold to Japan by Morinaga & Co in 1985 Orion has used it as a strategic product to find a firm position in foreign and domestic food markets With the current tastes of consumers is higher about low-fat and low-fat foods that are good for health, it will be an opportunity for countries around the world to develop pie products not only Korea 1.1.5 Purpose of inquiry and survey I was a full-time QC position officer at Bao Hung Confectionery Company My responsibility is to control the Omeli pie line So, with the knowledge I have to work and study at Bao Hung International Confectionery Joint Stock Company, to improve my expertise to apply, contact the knowledge of the field of study, accumulation of practical knowledge and a better understanding of the processing process I made the subject: "Survey of Omeli pie production process at Bao Hung international joint-stock company" 56 and recirculation air inside Steam (in direct heaters are products of combustion) are separated in each specific area Can be design as a heat recovery system The computer system is programmed to control the speed of the belt, the amount of heat to provide, the position of the air valves can automatically change the baking conditions in each region, so that it can produce a variety of cakes Omeli Pie is different colors and moisture - Advantages: Can be use to bake a variety of different cakes Productivity Precise process control Less labor-consuming, highly automated Using the heat exchanger at the outlet of the exhaust gas can thereby save energy and shorten the boot time The heat exchanger is used at the exhaust outlet so that it can save energy and shorten the warm-up time - Defect: High cost It takes a lot of space - Principle: The cake is transported on a conveyor, goes into the oven and goes through three baking stages: Stage 1: The cake is baked in an environment with high humidity (about 60 70%), and the temperature does not exceed 150°C In this stage, the gelatinized starch attracts a considerable amount of water, making drier cakes; denatured protein creates a structure for the cake; CO2 is formed by the decomposition of porous substance that escapes; The evaporation of moisture will gradually reduce the moisture content of the cakes; the outer layer has not yet become a hard shell but only a thin and flexible layer, so it has not affected the heat transfer, the product is cooked evenly, the moisture and CO2 escape easily not crack the cake Stage 2: oven temperature rises to about 190 - 205°C and lower humidity This phase continues the above changes, at the same time there are some chemical 57 changes such as caramelized sugars or melanoid reaction (reaction between reducing sugar and amino acids) to make the outer layer color golden brown, the aroma reaction for cakes Besides, the microorganisms are also destroyed Stage 3: is the final stage of the baking process, conducted and kept at a temperature of 170°C This is the period of fixing the product structure and the end of evaporation The equipment is indirectly heated by a gas generator It is not possible to use heated steam here because the steam temperature is only 100°C , while the baking temperature is nearly 200°C Indirect heat to avoid causing odor to the product Once out of the oven, the cake soft and fragile to cool before removing from the conveyor - Specifications: Cake with moisture content from 6.5 - 7.5% the humidity depends on the weight of each type of cake Cake weight : 7.3-7.4 g / piece Baking time: 7.5-8.5 minutes Wheel diameter: 58 - 62 mm, thickness 7mm Baking temperature: 120 - 270°C d The risk effect on quality product - Baking bread will measure the humidity, but after measuring the high humidity, it will cause the cake to live The way to treat it is to remove the entire back cake so as not to affect the quality - The phenomenon of burnt rear cake can be caused by too high temperature or slow speed of conveyor - Raw cake is the speed of conveyor faster than baking time 4.4.4 Cool Cooling is the opposite of heating It is the process of lowering the temperature from a high initial temperature to a final temperature equal to the ambient temperature or slightly higher 58 Most physical changes of cooling are opposite to heating, but there are also some non-reversible changes During cooling, microorganisms are checked regularly a Purpose of the process Bring the cake back to normal temperature, shape the product to prepare for the next ice cream clamping process In addition, the cooling process also has a process of moisture redistribution that makes the moisture in the cake evenly distributed b Cooling device The pie is moved on the conveyor belt at a rate of 15 minutes c The risk effect on quality product - After production workers with alcohol to clean the conveyor belt 70° to remove hazards of moldy bread because hygiene is not clean 4.4.5 Put the cream in between the two layers Figure 4.7: Put the cream in between the two layers 59 The process of put the cream is done by an automatic system with a suction cup and a positioning needle that works smoothly and accurately a Purpose: put the cream in between the two layers to prepare for chocolate coating b Rule: Using the machine put the creams , make the marshmallow uncoated and marshmallow-covered pieces together, Omeli Pie forming cake with the marshmallow centered c Device The device has a special effect device, which can suck the marshmallowuncoated piece of cake with pressure, then move the piece of cake and place it on top of the marshmallow-covered piece of cake After being put the cream in between two the layers , the cake is transferred through the pressing system This system works to squeeze the top piece of cake down to adjust the thickness of the marshmallow d The risk effect on quality product - In the process of cooking the cream, workers make the wrong process for excessive amount of water in the recipe, which affects the cooking cream does not reach moisture, the melting cream does not melt - The machine must be cleaned regularly because cream is very likely to smell sour and cause mold - Creamroom must have insect trap to limit big danger - Cream after aeration must be measured density to ensure the cream when placed in between two layers of cake will be fluffy evenly, no melting condition - Room temperature is stable - Conveyor belts are used 70°C of alcohol every time they are not manufactured to ensure the conveyor does not rise to the mold It is important effect to the quality of the product 60 4.4.7 Covered with chocolate Figure 4.8 : Cake after covered chocolate After the cake is put in the middle of the two layers of cake, it is passed through a chocolate melting system at a temperature of 40°C, making the entire 61 surface of the cake covered with a thin layer of chocolate coat to make the cake unique This Omeli pie , adds flavor, color to the product In the process, the cake is moved across a thin layer of chocolate solution Chocolate coating process is done through times to make sure chocolate covered the cake surface a Change - Physical: temperature increases due to the cake in contact with hot chocolate Then decrease during cooling - Physical chemistry: Cake with low moisture content can be hygroscopic when exposed to hot chocolate, increasing cake moisture, softening cake structure b Factors affecting - Temperature: Hot chocolate temperature suitable to be able to cover a thin layer evenly on the cake If the chocolate temperature is too cold, the viscosity is difficult to melt evenly on the surface of the cake The temperature is too hot to oxidize fat, burn chocolate - Conveyor speed: The cake is let through chocolate flowing into film at a moderate speed, enough for chocolate to be evenly coated on the surface Too fast speed can make chocolate unevenly, too slow speed can make chocolate layer too thick - The amount of chocolate: A moderate amount of chocolate, not too much will make people feel too sweet, not too little will not cover the surface of the cake, affecting the sensory value of the product The appropriate amount is 5.0 - 5.2 g / cake 4.4.8 Cooling a Purpose: to make chocolate cake crust frozen b Important transformations in the process - Physical change: the cake temperature decreases, there is a volume contraction of the chocolate crust - Physical and chemical transformations: Chocolate transition from liquid to solid Cake can be dehumidified as a crystalline fat and cause blooming on the surface of chocolate shells 62 Excessive cooling can increase the risk of chocolate freezing causing unwanted crystals to appear, making the chocolate structure soft and not smooth - Other variables: not significant c Factors affecting - Temperature: the temperature at the door of the cooling room may cause heat shock of chocolate crust, causing the crust surface to crack, not smooth - Relative humidity of the air: when the relative humidity of the air is over 80%, dark chocolate will absorb moisture The high humidity and conditions that cause moisture in the air to condense can cause blooming on the chocolate surface, making the casing less beautiful d Device The simplest refrigeration unit is a thermos convection room, the agent is the cold air circulating inside, in which the temperature at the center of the room is the smallest However, the humidity of the air inside the cooling room is quite high and the temperature at the door of the chamber will be able to shock chocolate heat To prevent the chocolate cover from being dehumidified, the air inside the cooling room should be dried and circulated continuously Air drying can be done by introducing fresh air that is lower than the temperature when using it After that, in the cooling room there will be air areas with temperatures of 13-19°C, 10 - 13°C and 13 - 15°C, which is the most appropriate temperature condition The conveyor that takes the chocolate cake into the cooling chamber is usually covered with plastic The belt should be thin so as to dissipate heat as much as possible, and so that it can easily pass through the pipe - where the product will separate from it Cooling time: if the crust around the cake is thin, the minimum cooling time may be about 10-15 minutes It should be noted that the air temperature around the bakery room is about 20°C and the relative humidity is below 65% 63 4.4.9 Packaging I a Purpose - Storage: after baking, it is easy to absorb moisture again when it is in ambient conditions, so it must be stored in waterproof oil packaging Packing for bread isolated environment outside air, help extend shelf life - Finishing: packaging is printed with eye-catching designs, contributing to the sensory value of the food The packaging is also inflated with inert gas to prevent it from falling apart Packaging also increases the aesthetics of the products for distribution to consumers easily Also helps to identify the date on the package, expiry date 12 months from the date of manufacture b Change - Cake does not have any significant changes c Device Figure 4.9: Packaging machine Film fitting lot Diaphragm conductor Aircraft shaped film Chain conveyor The trigger pulls the wheel Plot abdominal pressure 64 Knife Conveyor guide roller - Use the horizontal packaging machines - Principle of operation: The packaging film is inserted into the conveyor through the parts of the packaging machine then put on the aircraft to locate the film that the film is passed through two batches of abdominal pressure before being inserted into the cutter head The rotating balls are pressed against the underside of the packaging film and the cutter is constructed of small inner gearings fitted with heating resistors to secure the thermal presses for cutting The resistors are controlled by a heating system via a control clock Presses and cutters operate through a motor driven system, which is controlled by a touch screen There are parameters on the touch screen to set the speed of the cutter and the platens At the same time, the touch screen also controls the chain, the trigger of the wrapping machine to put the cake into the packaging and it also controls the eye to adjust the deflection of film of packaging 4.4.10 Packaging II Purpose packaging processes II : put cake into a bag or box in accordance with the way the product The purpose of packing crates: continue separating the cakes with the environment, creating a larger product, the convenient for transport arrange storage, handling and distribution In the process of packing, care should be taken to ensure the correct number of packages in a given carton 4.4.11 Cool storage Finished cake storage bins are stored on pallets and transported to a cool store The purpose of cool storage is to stabilize the product before it is market 65 4.4.12 Product quality criteria Table 4.2 : Criteria and prperty of Omeli Pie Criteria Property Sensory Featured Moisture 7– 7.5% Shape The middle circle has the marshmallow cream layer Water activity ≤ 0.73 total microorganisms like the air ≤10-4 CFU/g Coliform ≤104 E.coli ≤3 MPN/g S aureus ≤10 CFU/g Total yeast spores, mold ≤ 102 CFU/g Cl Perfringens 10 CFU/g Bacillus cereur 10 CFU/g Pd ≤ 0.2 mg/kg (Hg) ≤ 0.05 mg/kg (As) ≤ mg/kg 66 4.4.13 Methods of product inspection and disposal of defective products a Product testing method Table 4.3 : Product testing method Criteria Numbers Testing methods Net weight Weighing test weight Diameter Use calipers to measure the diameter Water activity Use water activity machine Moisture Use moisture machine The viscosity of chocolate Use a viscometer Checking for damage of package Try with water film Check print date Sensory Check the number of cakes in the box and Sensory in the carton Frequency check process/ installment Frequency of 10 microbiological months / installment testing at the center b Waste treatment methods The generated waste is classified into two categories - Discarded waste: products that fall on the factory floor, come into contact with workers' hands or dirty tools, burnt bread, etc are taken to the waste disposal area - Clean wastes: Clean wastes left on clean conveyors are put into plastic bags, recording full information of recycling in the polishing process with a certain percentage Regulations recycled bread to use only during the day 67 c Methods of storage and preservation of products Containers of finished products are stored on pallets and transported to a cool store for 24 hours before being released to the market The purpose of cool storage is to stabilize the product structure to prevent the product from being subjected to thermal shock when brought from cold room to hot air Products are stored in storage for up to months Pre-manufactured products will be sold first 68 PART V CONCLUSIONS AND RECOMMENDATIONS 5.1 Comment Through this report, I have found out the learned and uneducated knowledge, gained a lot of new knowledge during my internship at "Bao Hung International Confectionery Joint Stock Company" The output product quality is good, fully meeting the standards of food hygiene and safety and nutritional content Increasing production efficiency leads to competitiveness in the market Modern technology, easy to operate and maintain Waste from production processes is treated before disposal Input materials are quite large 5.2 Request During my internship at the company, I would like to have a few small recommendations as follows To improve the efficiency of the production process, it is necessary to train workers' expertise and regularly maintain old machinery 5.3 Conclusion To see and evaluate in detail a cake production process from raw materials to finished products and related production issues of a confectionery factory is indeed not so easy and requires a certain amount of time relatively long time Recognizing and evaluating only from the perspective of a student in food technology, it is enough to see that the application of science in production is not a problem too easily Here, I only briefly introduce in my understanding of a small production technology process per unit of the factory, have not learned, and approached more about a higher angle in technology because of a matter of time as well as inquiry However, it is also possible to basically introduce a technological process in the reality of a production plant on a transmission line, with modern equipment, directly consulted and helped from Germany It is considered the home town of Omeli Pie production 69 From the perspective of an application of technology in production, the Bao Hung confectionery factory has shown an important application of food technology, as well as other sectors such as electricity - electronics, automationfrom that, we can see that science is always born to practically serve human life Since then also shows the close relationship between the sciences together in the application process as well as partly affirms their relationship in the development process The company in the coming time also has many plans to ensure to improve production, increase production and quality of cakes to always maintain and develop the brand widely throughout the country and around the world in front of their basic advantages 70 REFERENCES [1] Le Van Viet Man (editor), Food Processing Technology, University Press HCM City Polytechnic, 2009 [2] Bui Duc Hoi (editor), Food Processing Technology, Science Publishing House and Engineering, 2006 [3] R Carl Hoseney, Principles of Cereal Science and Technology, 1994 [4] Company documentation ... understanding of the processing process I made the subject: "Survey of Omeli pie production process at Bao Hung international joint- stock company" PART LITERATURE REVIEW 2.1History of Bao Hung international... international joint stock company 2.1.1 Company introduction Name in transaction: Bao Hung International Joint Stock Company International transaction name: Bao Hung International Joint Stock Company. .. disposal company will collect and put it into treatment b Waste water treatment process Bao Hung has always been aware of the importance of treating wastewater to conserve water Bao Hung Company