Project report on,
Manufacturing process
Of

Supervisor; Project Designers;
Madam Anam Zaffar Syed Mohsin Hasnain Gillani(Leader)
(Total Quality Management) Asma Bushra Tooba Hasnain Hasan Mutahhar

M.Sc (Accounting & Finance) 3years Department of Commerce

Introduction to Nestle;
Nestle is the Switzerland based company working on the health, nutrition and wellness of people with a bright future scopes in their all departments.
Nestle is the world’s largest company who accommodated more than 100,000 people in its first year and they are providing the better opportunities for good health and for a better carrier to all. Nestle is working in world’s major countries with its variety of products and services.
Introduction to Maggie Noodles;
Maggi noodles are a brand of instant noodles manufactured by Nestlé. The brand is popular in Australia, India, South Africa, Brazil, New Zealand, Brunei, Malaysia, Singapore, Sri Lanka, Bangladesh, Pakistan, Fiji and the Philippines. In several countries, it is also known as maggi mee mee is Indonesian word for noodles. Maggi noodles are part of the Maggi family. Maggie family is the category of Nestle in which they are offering instant soups, stocks, and noodles.
Nestle offering different flavors of maggie noodles in different countries and the flavors they are offering in Pakistan are,
Maggie MASALA
Maggie CHICKEN
Maggie LEMON
Maggie BAR.B.Q
Maggie CHILLI
Maggie HARA MASALA
Maggie SOUPI NOODLES
Maggie CHATKHARA
Maggie noodles are basically made for those people who get busy in their life and don’t find time to Cooke meals. By considering this problem Nestle introduced ready to eat CUP NOODLES. Cup noodles are baked and made noodles they just need to be revolved in microwave oven for just two minutes and that get ready to eat with fully cooked ingredients.

History of Nestle;
Nestlé began in Switzerland in the mid 1860s when founder Henri Nestlé created one of the first baby formulas. Henri realized the need for a healthy and economical product to serve as an alternative for mothers who could not breastfeed their babies. Mothers who were unable to breastfeed often lost their infants to malnutrition. Henri’s product was a carefully formulated mixture of cow’s milk, flour and sugar.
Nestlé’s first product was called Farine Lactée (“cornflour gruel” in French) Henri Nestlé. The product was first used on a premature baby who could not tolerate his mother’s milk or other alternative products of that time. Doctors gave up on treating the infant. Miraculously the baby tolerated Henri’s new formula and it provided the nourishment that saved his life. Within a few years the first Nestlé product was marketed in Europe.
In 1874 the Nestlé Company was purchased by Jules Monnerat. Nestlé developed its own condensed milk to contend with its competitor, the Anglo-Swiss Condensed Milk Company. The Anglo-Swiss Condensed Milk Company made products like cheese and instant formulas. The two companies merged in 1905, the year after Nestlé added chocolate to its line of foods. The newly formed Nestlé and Anglo-Swiss Milk Company had factories in the United States, Britain, Spain and Germany. Soon the company was full-scale manufacturing in Australia with warehouses in Singapore, Hong Kong and Bombay. Most production still took place in Europe.
In Pakistan Babar Ali first purchased the shares of nestle in 1979 and in 1988 Nestle started its production in Pakistan and then in 1990 first time Nestle introduced magi noodles in Pakistan.

History of Maggi Noodles;
It is believed that Noodles were originated in North of China as early as 5000 B.C. After that noodles manipulated by different companies and different researchers of food. Noodles came in existence with the concept of healthy and nutritionist diet with typical cereals and diet ingredients. Later on in modern day Noodles were developed over the last 2000 years. Present day noodles were a unique contribution by the Han Dynasty (206 BC to 220 A.D.). The technique of making dried noodles were originated Yuan Dynasty (1271 to 1368 A.D.)
Merger with Alimentana S.A. (Maggi) 1947.Fried Noodles was invented & launched by Nissin, Japan in 1958. Nestle ventured into noodle business in Malaysia in 1972. Since then, noodle business has been growing.

Diagrammatic illustration of history;

1992
1995
1997
1999
2001
2002
2003

Air dried Noodles, Bicholim
Moga Fried Noodles Line-2
Moga Fried Noodles line-1
Air dried Noodles, Samalkha
Bicholim line converted to fried
Paam co-packing line, Noida
2004

2006-07

Ingredients;
Following are the ingredients Nestle using for the production process of magi noodles and these are the basic ingredients which are provided. * Wheat flour * Palm oil * Potassium chloride * Salt * Stabilizer * Emulsifier * Potassium carbonate * Sodium
How these ingredients are being utilized and under which processes they are passed for a final product it is discussed in remaining report.
Maggi Noodles variety;
Noodles variety is classified on the basis of technical composition or on the basis of flavors these categories are detailed listed down.

Flavors variety;
Maggi Noodles are available in a large assortment of different flavors. They are: * Original Flavor * Chicken * Curry (a healthier alternative is also sold in supermarkets) * Kari Letup ("Explosive" Curry) in Malaysia * Laksa Lemak (discontinued) * Tom yam * Chicken & Corn * Beef * Oriental * Masala * Prawn * Dal Sambar (whole wheat noodles) * Dal Atta noodles * Asam Laksa * Cheese * Pizza (only in Saudi Arabia and South Africa, was available for a period of time in Australia and New Zealand) * Sup Tulang (bone soup) (in Malaysia) * Chatpata * Tomato * Ruhi * Dashi * Koki * Kapi * Stronger Chicken * Crispy Chicken * Vegetable Atta Noodles (whole wheat noodles) * Shahi Pulao (rice noodles) * Chilly Chow (rice noodles) * Lemon Masala (rice noodles) * Mi Goreng Char Mee * Mi Goreng Kicap Bawang * Mi Goreng Pluz Asli * Capsica * Itik (duck) * Mi Udang Pulau Pinang' (was available in Malaysia) * Maggi goreng sedap * Boerewors (in South Africa)
Maggi noodles also produces instant noodles known as "Hot Bowl" noodles named "Cuppa Mania" in India. New drinkable Maggi noodle soups are also available.

Composition Variety Precooked Chinese Noodles are the main category in noodles composition and this category is further subdivided in two kinds on basis of frying: a) Fried Noodles b) Air Dried Noodles (Non Fried)
Fried Noodles are divided broadly into two other sub kinds on the basis of their taste and ingredients: i) One is provided with a separately attached tastemaker ii) Second is Seasoned Noodles

Air Dried Chinese Noodles;
These noodles consist of dried noodles accompanied by separate tastemaker Sachets. Precooked Chinese Noodles are eaten as they are by pouring hot water into seasoned Noodles.
Fried Noodles;
Fried Noodles & Dried Noodles are eaten by cooking them in boiling water 2-3 minutes adding some vegetables & meet a homely touch to them.
The most popular varieties of noodles are as follows which are most modified forms of noodles by Nestle magi.
Cup Noodles: Soaking in Hot water
Ready to eat Noodle: Three way of eating: * Directly crushing * Soaking in Hot Water * Boiling in Water.
Maggi 2 Minutes Instant Noodles:
2 min. Cooking M2MN Some Places 3 min. cooking M3MN (Nestle Turkey)

Manufacturing Process; First in manufacturing we will se the noodles technique which is most important to understand the whole manufacturing process. This technique can be shown as follows. This process explains the making of noodles in wet form the next finishing form is divided according to composition variety as we have discussed in the section of the composition variety. This can be shown by diagram as follows

Meanings of some technical words; Here are meanings of some technical words which are necessary to know to better understand the manufacturing process by a non-technical person. Kiriha -Slitting / Noodle making machine Scrap -Fragment of something useless remaining Scrape -to level the surface of thing for polishing Scraper -A tool for scraping Scraping -Any thing scrapped off.

Processing steps of Noodles line

Dough Mixing OBJECTIVES: Thorough mixing, uniform dispersion of ingredients to form a homogeneous mixture. To bring physical development of the gluten structure possessing to a required degree the desired characteristic of elasticity, plasticity and viscosity. Create small lumps (12 – 25 mm) of dough out of the homogeneous mixture which will facilitate sheet forming at the roller section. Noodles is made up of 80% of wheat flour and accordingly final quality of noodle is very much dependent on the quality of flour Four common analysis required are:- * Moisture * Protein * Ash * Wet Gluten Wheat flour indicator and critical factors which are as follows * Water pickup * Particle size & * Amylase activity Gluten index indicates the quality of wheat flour: High Gluten index => strong Gluten low Gluten index => Weak Gluten The falling number method is an internationally standardized method for the determination of alpha-amylase activity on flour. Low ( below 150) Falling number value=> High Amylase activity may contribute to stickiness. High falling number value=>low amylase activity indicates less starch damage & better sheeting characteristics. W value determined using the Alveo graph measures the dough extensibility/strength. The higher W value is, the greater is the biaxial extensibility of the standard dough. Higher extensibility improves sheeting conditions. Optimum flour protein content is required to achieve the desired elasticity and firmness of cooked noodles.At higher protein content elasticity firmness of noodles increases and vice-versa. Optimum protein content is 9.5 to 10.5%. Ash content in wheat flour determines the extent of extraction during milling operation.Ideally the extraction rate should be 60 to 65% during milling.Maximum ash content should be 0.5 to 0.6%.A higher ash content gives a gray colour to the final noodle and increases the lipase activity. Higher lipase activity can induce staleness. * Temperature and rate of starch gelatinization is very important with respect to cooking quality of noodles. * Starch should have adequate viscosity but not excessive paste viscosity. * High paste viscosity gives softer and more elastic noodles, Where as low paste viscosity gives firm and less elastic noodles. * Flour with high amylase and excessive damaged starch gives sticky noodles which has poor tolerance while cooking. First stage: * When the additive solution is mixed with the wheat flour, the volume increases slightly due to water absorption by the wheat flour which causes it to expand. * There is no dough formation at this stage, only a mixing with water. Second stage: * Dough formation commences with noticeable colour change to dull yellow . All the solution is now absorbed. Third Stage: * The volume of the dough is slightly reduced and the dough becomes lumpy ( 12-25 mm dough balls). * The dough mixing process is completed when the dough is difficult to break after clenching in the first a few minutes. * This indicates a proper gluten net – work has been formed. The dough now appears drier than when it is at the second stage. Mixing time varies between 18 to 22 minutes. Moisture of dough after mixing varies between 30 to 31%.

Rolling, Slitting and Waving; This is the process by which the mixed dough is rolled in rollers and the dough get the shape of thick sheets which is then passed from slitters which make the dough sheets more fine and equal from all sides and then these more fine sheets are transfered to the waver where the sheeta get the shap of spirls and the ringed form noodles which then pre dryied by air. Noodles can be disturbed in shape by the concept of locking and interlocking of layers which is shown as follows.

Good interlocking Non interlocking compact waves. Compact waves causes bad net weight and difficulty during frying also cause strand sticking after cooking.

Steaming; Purpose of Steaming is important as laces for shoes because this process gives the best binding to noodles. There are some following reasons for the steaming process, * During steaming gelatinization of starch in addition to denaturation of flour protein takes place. * The time and temperature of steaming is very important from product quality point view. * For steaming process dry saturated steam at 99 to 1000 C at a pressure of 0.2 - 0.3 kg/cm2 is used in the steaming tunnel * For food safety reasons culinary steam should be used during steaming. * Normally for standard fried noodle steaming time should be adequate to achieve >80% degree of gelatinization. * Degree of gelatinization of noodle starch is influence by the moisture content of the noodles. * Under same steaming condition a higher moisture content will give a higher degree of gelatinization. * After steaming generally a moisture pick up of 1 - 2% is there when saturated steam is used. Cooling; After steaming, noodles tend to stick and slightly drying up of noodles strands with the help of blower / fan over the conveyor is done to facilitate cutting of the strands by the portion cutter. Objectives of cooling: * As the cake leaves the fryer, they are quite hot (approx.) 1100C. * Before the cakes are packed, they must be cool otherwise would result in condensation forming inside the packing. Cutting, Folding & Distribution; This unit take the steamed noodles strands and forms the folded noodle cake. Speed of the cutter roller can vary which is required for net weight control. Cutting occurs above the Teflon rollers and very importantly the gap of the Teflon rollers should not be more than 6mm.
The cutting operation is performed by a stainless steel knife striking against a stainless steel backing roller. This should be adequately guarded to protect the personnel. The folding arm pushes the cut portion on to a deviator (distributor) belt and this folds the portion in half, forming the cake. The distributor carries the cakes and through the help of a Teflon coated chute transfers the cakes into the Gondola basket of the predryer. Diagrammatic Illustration of Cutting, Folding & Distribution;

Pre drying;
Objectives of pre drying * The specific objective is to remove around 1% of steam noodles moisture using hot air in a gondola type dryer. * The drying conditions are accomplish at a temperature of 55 to 600C and RH percent of 65 to 70. * The residence time in the dryer generally varies from 8 to 10 minutes.

Frying;
The main purpose of the frying is to preserve the noodles from effects of bacteria and fungai the other important purposes are as follows, * To rapidly dry the noodles to the required moisture content . * To cook the noodles to incorporate oil into the noodles. * Frying is accomplish by putting the noodle cakes in perforated steel basket mounted on a chain which is moved continuously through the hot oil in the fryer. * A second chain carrying a retaining cover/ basket prevents the cake from floating out of the basket and also helps to form a regular noodle shape.
Size of Noodle strands: A thinner noodle strands with a large surface area over volume ratio uptakes more oil.
Inlets and outlets frying temperature: A differential temperature of 5 -100C between inlet and outlet during frying prevents heat shock to cakes during entry and leads to lower uptake.
Wave formation : A compact wave formation will have a higher oil uptake due to entrapped oil. Loose strands in a cake gives greater surface area & higher oil absorption
Oil heating systems : Indirect heating systems (viz. shell & tube) heat exchanger tents to give lower oil absorption due to better controls.
Other factors : * Moisture of steam noodles, type and quality of flour & frying oil, particle size of flour, density of dough. The operating temperature during frying should be in the range of 125 - 1300C for inlet and 135 -1400C to outlet. * The frying time varies from 55 - 65 sec. To achieve ultimate cake moisture of 6.5 - 7%. * For a noodle cake of 80 gms approximately 25 gms of water is evaporated, since specific volume of atmospheric steam is 1.69 m3 per kg of water. * Each cake will release approximately 42 litres of vapours. This must be removed by the exhaust system. * The peroxide value (PV) of the fresh oil is a strong indicator of the oxidation status of the oil. * During weekend shutdown and during stoppages, when the fryer oil is put back into the used oil tank it is always beneficial to cool down to 70-800C to prevent increase in PV. * Noodle cake which comes out of fryer has high surface oil which leads to oil losses. * Air knife is install immediately at the fryer outlet to blow out excessive surface oil as quickly as possible, which helps in oil savings.

Wrapping & Channelizer;
12 cakes are routed to 3 packing lines. The wrapping process takes place by wrapping machines in very short time. The further proceedings are as follows,
Auto Cake Feeder: * Time the cake feeding with wrapper speed. * Avoids overlapping & breakages. * Adjustable timing & speed.
Sachet Dispenser: * Deposits the T.M. sachet on the cake. * Sachet aligning system. * Laminate speed and timing should match cake position and speed * Code is applied on laminate before packing * Adjustable speed for rooling and packing of cackes * Vertical and horizontal seals are applied. * Improper wrapping -- high rework/loss.