BÁO CÁO THỰC TẬP TẠI CÔNG TY BIBICA: HARD CANDY MANUFACTURING : HỆ CHẤT LƯỢNG CÁO BẢN TIẾNG ANH

HARD CANDY MANUFACTURING HARD CANDY MANUFACTURING Internship report Advisor Dr Dang Quoc Tuan Site supervisor Mr Pham Huy Trung INTERNATIONAL UNIVERSITY Name Vũ Hồng Thảo Nhi ID BTFTIU11002 BIBICA CORPORATION 1082014 1 Acknowlegdement First and foremost, I want to express my gratitude to Mr Pham Huy Trung – my site supervisor for his invaluable support and guidance His dedication and patience to explain all of my problems enable me to complete my work succesfully Iam grateful to Dr Dang Quoc T.

HARD CANDY

MANUFACTURING

Internship report Advisor: Dr.Dang Quoc Tuan Site-supervisor: Mr Pham Huy Trung

INTERNATIONAL UNIVERSITY

Name : Vũ Hồng Thảo Nhi ID: BTFTIU11002

BIBICA CORPORATION 1/08/2014

Acknowlegdement:

First and foremost, I want to express my gratitude to Mr.Pham Huy Trung – my site supervisor for his invaluable support and guidance His dedication and patience to explain all of my problems enable me to complete my work succesfully

Iam grateful to Dr Dang Quoc Tuan- my supervisor at the university for his neccesary advice and encouragement during my internship

Iam thankful to all the staffs and workers of the company for their kindness and cooperation during my internship as without their support, I could not manage to finish the internship

Last but not least, I want to say thank you to my seniors who I met during internship for being supportive and caring They also help contribute to my internship report as we exchange our knowledge

The result of this report require a lot of guidance and assistance from many people and Iam fortunate to have got this all along my completion of the the internship

Vu Hong Thao Nhi

II Internship result:

Hard candy processing:

o Quality control point

C Problems that might happen to candy

F Quality assurance test

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A History of development:

 In 1993, the company start its confectionary production with three main

production line: Candy production line that originated from Europe, biscuit production line with the APV technology of England On January 16th 1999, Bien Hoa Confectionary Corporation was founded by joining three plants: candy, biscuit, malt

 In 2000, the company develop its distribution system with new model as branches

in Hanoi, Ho Chi Minh, Da Nang, Can Tho, was established to satisfy the consumption requirements of customers At the same time, the company also invested in snack production line with the technology of Indonesia

 At the end of 2001, a cake production line was assembled with the capacity of

1500 tons and total budget of 19.7 billion In April 2002, a second factory was built at Sai Dong Gia Lam Industrial Zone, Hanoi

 In 2005, the company launch a new line of nutritious cookies called Mumsure for women in pregnancy and lactation, babies… under the consultant of Vietnam Nutrition Institute They also expand their investment to beverage with cereal powder products named Netsure and Netsure light

 On January 17th 2007, Bien Hoa Confectionary Corporation officially changed its name to Bibica Corporation

B Organization structure:

 Company‘s organization structure:

 Factory’s Candy workshop’s organization:

Board of supervisory Board of director

CEO

Head

accountant

Director of R&D

Technical director

Malt workshop

Candy workshop

Director

of marketin

g

Director

of purchasin

g

Ha Noi

Can Tho

Da Nang

HCM

CEO assistant

Bread workshop

2

Bread Workshop

1

WO

Sale manager

Director

of productio

n

Workshop manager

Shift manager

Workshop vice manager

Processing manager

Wrapping manager

Finishing manager Bagging

manager

There are a variety of brands include:

Lollipop Welly , Welly , Volcano , Migita , Tu quy ,

Figure 1: Various types of hard candy

 Soft candy:

There is a variety barnds of soft candy: Sumika ,welly, Quê Hương, Michoco…

Figure 2 : Sumika soft candy

Figure 3 : Beme gummy and Cherry stick candy

 Nutritious functional foods:

Bibica Corporation was certified with HACCP Certificate by Quacert Certification Center in

2003 In 2004, the company was awarded with Gold Medal for Safe and Qualified food for Public Health by the Ministry of Health It also received ISO 9001:2000 and ISO 9001: 2008 Standard by Ho Chi Minh Certification Authority Office in 2007 and 2009, respectively

Bibica’s candy was certified as The Best Products of Vietnam for 2010 … etc

Figure 6: Function foods

The factory is divided in to 4 main sectors: Ingredient room, processing area, wrapping area and packaging area

 Processing area:

Figure 8 : Processing area layout Entrance

Material entrance

Door

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 Wrapping area:

Figure 9: Wrapping area layout

Unwrapped hard candy

Unwrapped hard candy for deposit line

Door

 Packaging area:

Figure 9: Packaging area layout

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II Internship result:

Hard candy processing:

A Ingredients:

 Sucrose: (C12H22O11, M=342, d=1.5879 g/cm3)

o Role:

- Sucrose attribute to the sweet flavor, color and taste of candy

o Physical and chemical properties:

- Invert sugar and degraded products of sucrose absorb water tremendously when heated more than two hours or, in short time but at high temperature, which

eventually cause burning of candy

Physical – chemical standard

RE,RS Sugar White color or beige

Fine crystal

Moisture (%) <= 0.1 Color (I0 ) <= 50

RS Sugar Crystal has uniform

shape, sweet tatste ,

no strange smell

Moisture <=0.15 Color < 150

Preservation condition

Normal condition Expired date 12 months

 Corn syrup:

- Corn syrup is a necessary ingredient in making hard candy It is produced from the hydrolysis of starch of grains and … like corn syrup, potatoes, wheat The main role of corn syrup is to stabilize the solution, prevent it from crystallization and keep the dry mass of solution above 75% so that yeast and mold do not grow and cause spoilage Corn syrup also help maintain the chemical, physical

properties as well as structure of candy by increasing the viscosity, chewiness Bibica produce their own corn syrup for processing DE is used to evaluate the esterificarion of stacrh The higher the sweetness , the higher the DE and vice versa

- Components of corn syrup:

Table 3: Quality standard of citric acid

Standard Requirement Dry mass content 80-85%

Reducing sugar (Rs) 35-40 %

Organoleptic standard

Physical – chemical standard

Acid citric White color, no

impurities, should

be transparent when being dissolved in water

Moisture(%) <=9 Amount of

anhydrous acid

>= 88 Bagging 25kg/bag Expired date 12 months Preservation

condition

Normal condition

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 Condensed milk:

Condensed milk is added in order to enhance flavour of candy The condensed milk used in the proceesing is made at the workshop and added after the syrup solution is done

Table 4: Quality standard of condensed milk

Condensed milk Organoleptic Chemical- physical standard

Liquid form, ivory white color, sweet taste,

no strange ordor

Dry mass(%) 73-75 Saccharose (%) 42-44

Acid lactic (%) < 0.4

 Additives:

 Colorants:

 Colorants used in hard candy processing are synthetic color which can be dissolved easily in water They are imported from Korea, Japan and China Their main role in the production is to create a desired color for hard candy The amount of colorants added will follow the appointed formular , depend

on each type of candy

 List of colorants used in hard candy processing:

 List of flavor used in hard candy processing:

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B Processing:

Material

Creating syrup solution

 Interpretation of the process:

1 Creating syrup solution:

This is the first step in manufacturing hard candy The syrup solution consists of sugar,water, corn syrup and milk solution, this milk solution is produced by the candy workshop

- Sugar changes from its crystal form to liquid

- The temperatures of the solution increase

- Dry matter content of solution increases

o Chemical changes:

- Formation of invert sugar resulting from the hydrolysis of saccarose

- Caramelization might occur due to improper heating and stiring resulting in dark color of syrup , which may affect organoleptic values

of solution is about 105 -1100C Next, stirring is halted and the corn syrup is pumped into the tank through a series of pipes Then the solution continue to be stirred and heated for 8- 10 minutes with the vapour pressure of 6kg/cm3 When the solution is fully dissolved, the stirrer is turned off, milk solution is added and the solution is pumped to the intermediate tank where it is stirred by stiring blade to prevent the solution from thickening before being cooked

 Factors affecting syrup creation:

Temperature plays a crucial role to the sugar dissolving speed The higher the temperature, the higher the speed and the sugar dissolving rate is enhanced

Mass of water that is used for this stage is usually account for one – third of the sugar If there is little water, sugar crystal shall not be dissolved completely In contrast, if there is

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too much water, more energy will be needed for the evaporation in the next step indicating longer time, which impacts on the productivity and quality of candy

 Quality control parameters:

o QC1: Workers will weight the material for each batch of candy based on the formular

o QA1: Staffs of quality assurance department will collect sample- syrup solution at site and examined these parametes :

 DE:

- Candy with glucose : 18-26

- Candy without glucose: 14-22

 Physical and chemical changes:

 Physical changes:

- Temperature and viscosity of the candy mass increase

- Content of dry mass increase

 Chemical changes:

- Caramelization of sugar takes place vigourously at high temperature

- Formation of invert sugar resulting from the hydrolysis of saccarose may occur

 Quality control parameters:

Workers have to check these parameter carefully every 2 hours:

 Physical and chemical changes:

Physical: temperature of the candy decreases

 Factors affecting candy quality during mixing:

The candy mass should not be mixed too vigorously as air might be absorbed and create bubbles which might influence organoleptic values and reduce the quality of candy In addition, flavour and color are volatile compound so they may evaporate if the mixing is not done properly

 Quality control parameters:

QC3 :Workers have to weight accuratelly amount of flavour and colorant based on formular

 Physical and chemical changes:

Physical : Temperature of candy mass decreases while its viscosity increase

 Requirement:

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The candy mass should be cooled down immediately and its texture must be flexible for

the size and shape forming

 Procedure:

There are two stages in the first cooling Firstly, the candy mass will be cooled at the cooling table Cooling factor is cold water at 200C During the cooling at cooling table , the surface of the candy mass that contact with the table must be folded to the center of the mass continuously until the temperature of the candy is reduced.Temperature of the candy mass after cooling at cooling table is 70-800C Secondly, the mass of candy is transferd to kneading machine where it is folded and circulated continuously on the cooled rotary table by a star fruit – shapedrollerso that it can have a uniform texture The candy mass leaving kneading machine with the temperature of 70 – 750C

 Factors affecting the quality of candy mass:

If the temperature of water that is used for cooling is too low, there will be frost on the suurface of the candy mass In addition, cooling should not takes too long or the recrystalization of sugar will occur

5 Size and shape forming:

Size and shape forming are performed on a line of machine that include batch roller, rope sizer and die forming machine

of four pair of cog- wheels Distance between each pair of cog – wheel decreasesgradually leading to the decline in diameter of the candy string Finally,die forming cut the candy strings into piece of candy with desired shape

 Factors affecting candy quality :

Speed of rope sizer and die forming machine must be approriate, if the speed of rope sizer is faster than die forming machine’s , string of candy shall break leading to the short

of candy On the other hand, string of candy will accumulate and affect the stretching if speed of rope sizer is slower than forming machine

 Quality control parameters:

QC4: Workers will check the amount of candy which is about 60 – 72 pieces/200 g for hard candy

6 Second cooling:

 Purpose:

The candy in this stage is soft and easy to be deform Second cooling help the candy become more settle and brittle

 Physical and chemical changes:

Physical changes: temperature of the candy decrease

 Requirement:

Candy shoud be cooled properly so that they will not be sticky and deform

 Procedure:

After shaping, the temperature of candy is about 65-700C In this state, candy are easy to

be deform Therefore,they must be cooled down by cooling conveyer The room ought to have cool temperature (20-250C) and humidity is <50%.Exhaust fan of cooling conveyer will absorb cool air from surrounding to cool down the candy The temperature of candy after cooling is 25 -300C

 Quality control parameters:

QA2: Staffs of quality asurrance department will collect the sample of each shift and examine these parameters:

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8 Wrapping:

 Purpose:

The point of wrapping is separating the candy from interacting with environment outside

so that they will not absorb moiture or contanminate with organism In short, wrapping help extend shelf life and enhance organoleptic values of the products

 Requirements:

- Amount of candy must reach required number

- Candy that are unqualified must be eliminated

- Seal of the wrapper has to be tight and firm

- Wrapping film ought to be cut with accurate size and position

 Procedure:

Candy kept in nylon bag is poured into the hopper of wrapping machine As the hopper vibrates, candy drop onto distributing tray The distributing tray has 2 disks that rotate at different speed One disk has holes to keep candy the other has cone shape There is also

a sweeping brush which helps candy distribute on the tray Candy in the holes will be dragged by load chain to a film folding box where they are wrapped and sealed by pairs

of vertical and horizontal heating wheels

 Quality control parameters ;

QA3: after cooling , the candy is considered as nearly complete, staff of quality assurance department will collect sample every 2 hours and examine these parameters below to ensure that the candy is qualified enough to proceed with wrapping:

o Moisture: (%)

- Tu quy : <= 1.5

- Volcano : <= 2

- Lollipop: <= 2.5

o Ash ( check 6 times for every 3 months ): <=0.1

QC5 : workers will check the quality of wrapping by touching and observing

- Amount of candy in one bag must reach required number

- There must be an expiration date on the lable

- The seal on the bag has to be tight, firm

- Wrapping film ought to be cut with accurate size and position

 Procedure

Candy are poured into the hopper of the bagging machine When the hopper vibrates, the candy will drop onto the rack where they are elevated by bucket conveyor and poured into the central tube Next, they will be dropped a scale in which they are weighted accurately to obtain a demanded amount of candy for one bag which is 650g Then they are discharged into a bag and transfered by conveyer to sealing machine

 Quality control parameter:

QC6: Mass of candy bagg and quality of bagging will be exmined by workers

Workers will collect candy bags and put them into boxes

1 Quality control parameters:

QA4: Staff of quality assurance department will collect sample to check net weight and hygiene criteria

QC7: Works will check to make sure that the number of candy bags in one box is correct

o Adjust the heating time

o Ingredients that are added must be measured carefully

o Cleaning/sanitizing the tank carefully before cooking a new batch

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o Cooling must be carried out quickly

2 Premature candy:

a Reasons:

o Syrup solution has low Bx values

o Too much syrup enters coiled tube, heating and vaccumm pressure is not enough to evaporate all the moisture of syrup

o Steam pressure and vaccuum pressure are too low Low steam pressure cause low temperature, moisture in syrup can not evaporate completely Low vaccuum pressure hinder the evaporation leading to the high moisture content of candy

b Measurements:

o Dissolve syrup that has fine Bx value

o Regulate amount of syrup entering the cooker

o Adjust vaccuum pressure carefully

 Year of production: 1974

 Origin : Poland

 Structure: The cooker is a spherical tank that has stirrer and engine