parle-g

INTRODUCTION
A long time ago, when the British ruled India, a small factory was set up by
Mohanlal Dayal Chauhan in the suburbs of Mumbai city, to manufacture
sweets and toffees. The year was 1929 and the market was dominated by
famous international brands that were imported freely. Despite the odds and
unequal competition, this company called Parle Products, survived and
succeeded, by adhering to high quality and improvising from time to time.
A decade later, in 1939, Parle Products began manufacturing biscuits, in
addition to sweets and toffees. Having already established a reputation for
quality, the Parle brand name grew in strength with this diversification. Parle
Glucose and Parle Monaco were the first brands of biscuits to be introduced,
which later went on to become leading names for great taste and quality.

History
Parle-G or Parle Glucose biscuits, manufactured by Parle Products
Pvt. Ltd, are one of the most popular biscuits in India. Parle-G is one of the
oldest brand names as well as the largest selling brand of biscuits in India.
For decades, the product was instantly recognized by its iconic white and
yellow wax paper wrapper with the depiction of a young girl on the front.
Parle-G has been a strong household name across India. The great taste,
high nutrition, and the international quality, makes Parle-G a winner. No
wonder, it's the undisputed leader in the biscuit category for decades.
Parle-G is consumed by people of all ages, from the rich to the poor,
living in cities & in villages. While some have it for breakfast, for others it is
a complete wholesome meal. For some it's the best accompaniment for chai,
while for some it's a way of getting charged whenever they are low on
energy. Because of this, Parle-G is the world's largest selling brand of
biscuits. Launched in the year 1939, it was one of the first brands of Parle
Products. It was called Parle Glucose Biscuits. The incredible demand led
Parle to introduce the brand in special branded packs and in larger festive tin
packs. By the year 1949, Parle Glucose biscuits were available not just in
Mumbai but also across the state. It was also sold in parts of North India.
The early 50s produced over 150 tons of biscuits produced in the Mumbai
factory. Looking at the success of Parle-G, a lot of other me-too brands were
introduced in the market. And these brands had names that were similar to
Parle Glucose Biscuits. This forced Parle to change the name from Parle
Glucose Biscuits to Parle-G. Originally packed in the wax paper pack; today it
is available in a contemporary, premium BOPP pack with attractive side fins.
The new airtight pack helps to keep the biscuits fresh and tastier for a longer

period. Parle-G was the only biscuit brand that was always in short supply. It
was heading towards becoming an all-time great brand of biscuit. Parle-G
started being advertised in the 80's.
It was advertised mainly through press ads. The communication spoke
about the basic benefits of energy and nutrition. In 1989, Parle-G released
its Dadaji commercial, which went on to become one of the most popular
commercials for Parle-G. The commercial was run for a period of 6 years.
The goal was to spread joy and cheer to children and adults alike, all over
the country with its sweets and candies. Since then, the Parle name has
spread in all directions and has won international fame. Parle has been
sweetening the lives of people all over India and abroad.Apart from the
factories in Mumbai and Bangalore, Parle also has factories in Bahadurgarh,
Haryana and Neemrana, Rajasthan. These are the largest biscuit and
confectionery plants in the country. Additionally, Parle Products also has 10
manufacturing units and 75 manufacturing units on contract.
The company's slogan is G means Genius. The name, "Parle-G", is derived
from the name of the suburban rail station, Vile Parle which in turn is based
on village Parle in olden days (there is also area called Irle nearby where the
Parle Agro production factory is based).
This popular biscuit is primarily eaten as a tea-time snack.Parle-G is the
largest selling biscuit in the world. It has 70% market share in India in the
glucose biscuit category followed by Britannia, Tiger (17-18%) and ITC's
Sunfeast (8-9%). The brand is estimated to be worth over Rs 2,000 crore
(Rs 20 billion), and contributes more than 50 per cent of the company's
turnover (Parle Products is an unlisted company and its executives are not
comfortable disclosing exact numbers). Last fiscal, Parle had sales of Rs
3,500 crore (Rs 35 billion). It also is popular across the world and is starting
to sell in Western Europe and USA

HOW PARLE FOUGHT TO MAKE BISCUIT AFFORDABLE

TO ALL
Biscuits were very much a luxury food in India, when Parle began production
in 1939. Apart from Glucose and Monaco biscuits, Parle did offer a wide
variety of brands.
However, during the Second World War, all domestic biscuit production was
diverted to assist the Indian soldiers in India and the Far East. Apart from
this, the shortage of wheat in those days, made Parle decide to concentrate
on the more popular brands, so that people could enjoy the price benefits.

Thankfully today, there's no dearth of ingredients and the demand for more
premium brands is on the rise. That's why; they now have a wide range of
biscuits and mouthwatering confectionaries to offer.

THE STRENGTH OF THE BRAND

Over the years, Parle has grown to become a multi-million US Dollar
company. Many of the Parle products - biscuits or confectionaries, are
market
leaders
in
their
category.
Today, Parle enjoys a 40% share of the total biscuit market and a 15% share
of the total confectionary market, in India. The Parle Biscuit brands, such as,
Parle-G, Monaco and Krackjack and confectionery brands, such as, Melody,
Poppins, Mangobite and Kismi, enjoy a strong imagery and appeal amongst
consumers.
In this way, by concentrating on consumer tastes and preferences and
emphasizing Research & Development, the Parle brand grows from strength
to strength.

The Quality Commitment

Parle Products has one factory at Mumbai that manufactures biscuits &
confectioneries while another factory at Bahadurgarh, in Haryana
manufactures biscuits. Apart from this, Parle has manufacturing facilities at
Neemrana, in Rajasthan and at Bangalore in Karnataka. The factories at
Bahadurgarh and Neemrana are the largest such manufacturing facilities in
India. Parle Products also has 14 manufacturing units for biscuits & 5
manufacturing units for confectioneries, on contract. All these factories are
located at strategic locations, so as to ensure a constant output & easy
distribution. Each factory has state-of-the-art machinery.
All Parle products are manufactured under the most hygienic conditions.
Great care is exercised in the selection & quality control of raw materials,
packaging materials & rigid quality standards are ensured at every stage of
the manufacturing process. Every batch of biscuits & confectioneries are
thoroughly checked by expert staff, using the most modern equipment.

THE MARKETING STRENGTH

The extensive distribution network, built over the years, is a major strength
for Parle Products. Parle biscuits & Sweets are available to consumers, even
in
the
most
remote
places.
Parle has nearly 1,500 wholesalers, catering to 4, 25,000 retail outlets
directly or indirectly. A two hundred strong dedicated field force services
these wholesalers & retailers. Additionally, there are 31 depots and C&F
agents supplying goods to the wide distribution network.
The Parle marketing philosophy emphasizes catering to the masses. They
constantly endeavor at designing products that provide nutrition & fun to the
common man. Most Parle offerings are in the low & mid-range price
segments. This is based on their understanding of the Indian consumer

psyche. The value-for-money positioning helps generate large sales volumes

for the products.
However, Parle Products also manufactures a variety of premium products
for the up-market, urban consumers. And in this way, caters a range of
products to a variety of consumers.

RAW MATERIAL USED

Wheat flour
Sugar
Partially hydrogenated edible vegetable oils
Invert syrup
Leavening agents (503 Baking powder)
Milk solids
Salt
Emulsifiers (E 322 or E 471 or E 481)
Dough conditioners (E 223) and contains added flavors.

PROCESS LAYOUT OF PARLE PRODUCTS LTD.

PARLE G is made at parle products ltd. at vile parle.

First of all the parle products buys RAW MATERIAL from the various suppliers and
stored into the store room. This raw material is then sent to laboratory for testing
and after testing only it is used for manufacturing. The raw material consist of
Wheat flour, Sugar, Partially hydrogenated edible vegetable oils, Invert syrup,
Leavening agents (503 Baking powder) Milk, solids Salt Emulsifiers (E 322 or E 471
or E 481) and Dough conditioners (E 223).
Such a mixture of raw material is taken and mixed into STEPHAN MIXTURE, which
is high power mixture machine. Specially made for mixture of dough, from which
the mixture is passed to molder called ROTARY MOULDER. Through that molder
approximately 10,000 come out in a minute. Molder had 260 cups fitted in it which
gives shape to the biscuits and an impression embossed on it of parle-g.
From rotary molder the dough is passed through a 260 feet long OVEN which is
approximately 340* c. In oven there are three stages to be followed
Removal of moisture.
Building the structure of biscuits.
Colorings of biscuits take place.
From oven the hot biscuits are placed on the COOLING CONVYOR, which is 260 feet
long and the biscuits continues to run on it for 5 to 7 minutes so that the biscuits
become cool and all the moisture that biscuits contain gets evaporated. And
because of the above reason the factory has S FLOW LAYOUT in the factory.
The conveyor continues to move to COUNTING UNIT where biscuits are counted and
seen that it is going on properly or not. The conveyor continues till the biscuits
reach the STALKING TABLE at which the biscuits are packed in very orderly manner.
From cooling conveyor sum biscuits are diverted through AUTO FEEDING MACHINE
to another stalking machine where packing is done. From stalking table the biscuits
are moved on conveyor to MULTI PACK WRAPPING MACHINE were 16 biscuits are
packed into a regular parle g wrapper so that the weight of 16 biscuits comes up to
100 grams.

Then 24 packets of parle g biscuits are packed into a POLY BAG. And after packing
it into poly bag it is sent to SEALING MACHINE where it is sealed, Then it is sent to
CORRUGATE BOX SECTION in which 6 poly bags are placed and then the boxes are
kept on conveyor and sent to DISPATCH SECTION from where the biscuits are sent
to various places in India and all over the world.

INVENTORY
The inventory of the company that is the raw material is of a week. They store such
inventory in store room and then are sent for testing in laboratory and after testing
it is sent for production.

SHIFTS
There is nearly 10,000 employees working in the company and are working in three
shifts.35,000 tons of biscuits are manufactured in a day of one particular product,
and there are such nine product manufactured in the factory.

WASTAGES
There are two type of wastage in factory. First is the waste materials fallen on
ground. Such waste material is of 1% which is marginal and acceptable which goes
into total waste. Second types of waste are the biscuit collected in tray of the multipack wrapping machine, since these biscuit are broken they are not packed and
sold to the customer but collected in other tray and sold as broken pieces and sold
for less price for cattle feeding.

LOOSE BISCUIT
On the stalking table one to two rows of baked biscuits are kept aside for selling it
as loose biscuits. They are normally assumed to be damaged biscuits but they are
not damaged or broken but company keep such loose packets of biscuits to sell it to
the local people for marginal rate of 33 Rs / kg.

FOLLWING ARE THE MACHINERY USED IN MANUFACTURING

STEPHEN MIXER
The Stephan TK Mixer is an ideal component to fully automatically feed the downstream make-up equipment for biscuits, bread, rolls, buns, cake, sweet goods,
cookies and crackers.

ROTARY MOULD

structure in corrosion-proof; anodized aluminumand Aisi 304 stainless steel

satin stainless steel paneling

swivel wheels and support feet

trays loader with automatic chain feed

feeder roller anodizedaluminum

1.00 kW speed validator

COOLING CONVEYOR
The biscuit coming from stripping conveyor is directed on to the cooling
conveyor to transfer the heat in the biscuit to atmospheric air as it is passing

on it. The total travel of the cooling conveyor is 1.5 times the oven length.
As per need specifications it need the travel of 150 ft.
LAMINATOR
Laminators are generally used for production of all kinds of hard biscuits,
crackers and cocktail snacks. With laminator it is possible to create a puffy
pastry-like structure, which is of decisive importance for the quality level and
consequently for the sales success. Laminating of Dough band improves the
weight/volume
ratio
considerably.

BISCUIT BAKING OVEN

The oven body consists of steel steam tight tunnel with equally divided zones
of the radiators. Stainless steel expansion joints are provided between these
zones in order to eliminate the expansion of the oven section. The inspection
doors are provided for inspection of the baking goods during the process.

Baking System:
The baking in the heating chamber takes place by radiators located under
and above the wire mesh band which distribute heat for uniform baking. The
recirculation heating gases of these radiators can be controlled for each zone
separately. The closed recirculation system is having slight vacuum so that
combustion gases cannot enter into the baking chamber. The ventilating fan
is for circulation of the heating gases through the recirculation system and
thermostatically controlled burners provide the set temperature of the
heating gases.
ROTARY CUTTER
The single head rotary cutter prints fine design on a continuously fed dough
sheet and also cuts out the individual dough piece. The unit powered by
1.5KW helical geared motor and speed controlled by AC frequency controller.
Drive is given to cutting roller only to accommodate different sizes of dies in
this machine.
COUNTING UNIT
The counting unit counts and see that the biscuit making process is going
fine or not, i.e. as per the program set in the machine, program is set as per
the grams required. Generally 16 biscuits are taken by the counting unit so
that it leads to 100 grams.
MULTIPACK WRAPPING MACHINE
This machine helps in wrapping the biscuits on the particular wrapper fixed
on the roller of the machine. The wrapper is feed into the machine and the

sealing of the wrapper is done by four heater roller, which is fitted on the
machine. This heater roller heat up the plastic and seals the packet. And at
the same time the jaw cutter cut the packet on the cutting edge marked i.e.
as per the grams of the packet which is feed in the automatic machine (100
120, 120 150, 150 -170, 170 - 190). The packets coming out from the
wrapping machine in a minute is programmed in computer and can be
changed as per the need.
POLY BAGS
Poly bags contain 24 packets of parle g biscuits in one poly bag. There are 4
workers employed on this section who take care of the work by putting 24
packets of biscuits in the bag and forwarding it to sealing machine section.
SEALING MACHINE
The sealing machine has heater rod for sealing the poly bag in which 24
packet of biscuit are placed, and it have a conveyer belt on other side so
that when the poly bag passes through the heater and get sealed then it is
passed to the tapping machine.
TAPPING MACHINE
Six such poly bags are placed in one such corrugated box and the box is
passed through the tapping machine where are tapped and then sent
through a long diversion conveyer belt. This belt helps to transfer the box to
the dispatch section directly. 36 boxes are arranged on pallet in the dispatch
section, from where they are transferred to the various dealers all over the
India and worldwide.

Parle-G Products

BISCUITS

Snacks
Parle-G
Monaco smart
Krack jack
Monaco
Kreams
Hide & Seek
Hide & Seek Milano
Hide & Seek Bourbon
Parle actifit digestive marie
Milk shakti
Namkin

Sweets
Melody
Mango bite
Kaccha mango bite
Chos
Poppins

chips

20-20 cookies
Golden arc

Quality
The Care is taken at every step to ensure the best product of long-lasting
freshness. Every batch of Biscuits, Confectionaries & Snacks are thoroughly
checked by expert staff using the most modern equipment. This ensures
consistent and perfect quality across the nation and abroad.

IMPORT EXPORT
The immense popularity of Parle products in India was always a challenge to
their production capacity. Now, using more modern techniques for capacity
expansion, we have begun spreading their wings and are going global. Parle
biscuits and confectionaries are fast gaining acceptance in international
markets, such as, Abu Dhabi, Africa, Dubai, South America and Sri Lanka.
Even the more sophisticated markets like USA & Australia, now relish Parle
products.
As part of the efforts towards a larger share of the global market, Parle has
initiated the process of getting ISO 9000 certification. Many Parle Products
have also won Gold, silver and bronze medals at the Monde Selection.

CORPORATE SOCIAL RESPONSIBILITY:

As a part of Corporate Social Responsibility Policy Parle is keenly involved.
In the overall development of younger Generation with focused endeavor.
To build New Face of India and spread Happiness & joy all over.