Long Island Nutritionals

INTERNSHIP REPORT

ADITYA PATEL
 Manufacture of Gummy bears
● Long Island Nutritionals is the first company in India to produce medicinal
gummy bears.

● Multivitamin and calcium gummy bears are manufactured.

● I worked in the factory located in the umbergaon district for a period of

two weeks

● I took active part in the manufacturing process which I have documented

in this presentation.

● The machinery has major scope for improvement since the current
machinery is outdated and less efficient.

● There are some suggestions which I have made so as to help increase

efficiency of the manufacturing process after closely observing the same.
 Manufacturing process

● Dispensing:
•All materials are dispensed in stagewise sequence as per dispensing
sheet
•Weight of all materials is recorded.
•Dispensed materials are transferred to the manufacturing area.
 Cooking and Mixing

● Hot water is charged in cooking kettle and agitator is started.

● Suger is allowed in the cooking kettle and solution is allowed to boil at 90-110 C
● Glucose solution is added to boiling sugar syrup and allowed to boil
● Pectin and sugar are taken in separate containers and made slurry by addition of water and
added in the cooking vessel and the solution is boiled
● The solution is boiled till required brick value is obtained.
● The syrup is transferred to holding tank through feed pump.
● Another lot is manufactured in another cooking vessel by
following the 4 previous steps and on completion is transferred into
holding tank through the feed pump.
● Orange flavour, yellow colour and multivitamin premix are
added to the holding tank with continuous mixing.
● Citric acid is added to the holding tank with continuous mixing.
● The water content of solution of mixing tank is measured and
recorded.
● The weight for depositing is calculated by considering the
water content of the solution.
 Pouring

• Starch trolley is collected from

hot room for pouring.
• Pouring of solution is carried out
and weight measures are carried
out during the process. They are
recorded in BMR. The weight
checks are carried out every hour
at minimum two lines. After
completion of pouring the trolley
is labelled and transferred to the
drying room. Details are recorded
in BMR
 Drying

● Drying of gummy is carried out in hot room at specified time and

temperature.
 De dusting

• Physical status of gummy kept in

drying room is checked for
proper folding and after a
specified time all trolleys are
collected for de-dusting..
• All trolleys are de-dusted and
gummies are seperated from
starch. The gummy is weighed
and its BMR is recorded.
• Gummy is de-dusted using de-
dusting machine and collected in
proper container.
 De dusting

● The gummies collected must be transferred into containers and taken

to the next step of the process, a machine integrating both processes
can be used to reduce manhandling.
 Coating

● The required coating of gummy is carried out lot wise in coating pan and
collected in the container. The weight of output is recorded.
 Inspection

• Inspection of gummy is carried out manually or on the inspection belt.

The weight of the good gummies and rejected gummies is noted down in
BMR. The good gummies are filled in containers and stored in required
storage conditions. The good gummies are handed over to person in
charge of intermediate store and the rejected gummies to in person
charge of rejection store.

• The weight of 1 kg gummy bears is taken out, the gummies are counted
and recorded in BMR. This is required for converting weight of output to
quantity in numbers.
Current yield of calcium gummy bears : 68.33%

Total Material Cost 134.29

Total Conversion Cost 160

Total production Cost 294.55

Packaging material cost 9.70

Cost per 75g Pack 24.43

MRP 150
Current Yield for multivitamin gummy bears : 63.33%

Total Material Cost 209.81

Total Conversion Cost 160

Total production Cost 370.06

Packaging material cost 9.70

Cost per 75g Pack 28.20

MRP 200
 Drawbacks of current manufacturing facility

● Unable to produce a very high yield because:

•The equipment lacks automation and is outdated

•Due to lack of automation there is loss of produce on account of manhandling.
•Major loss of yield in transferring the premix into the moulds, separating starch
from gummies and de-dusting of gummies.
•Automated machines known as starch moguls can be purchased to replace the
machines which require substantial manual labour to decrease manhandling.

A few machines given below can be purchased to improve the yield with a
minimal recovery time for the capital spent.
 T-Gel Automated Track System (ATS)

● Tanis Confectionery has designed an automatic track system (ATS) to move pallets
. with moulding trays from the moulding line to the conditioning room/area and
reversible from conditioning room/area to moulding line. The robots of the moulding
line will stack the trays on a pallet to a certain height. The pallets can have three stacks
with a height of 50 to 70 trays.
• This machine helps reduce manhandling by eliminating the need for labour
• It leads to fewer tray damage and less moulding line stops which reduces the time
taken
 Tannis Weigher

● The Tanis Weigher is a unit for the preparation of the premix. It works by weighing
ingredients (liquid and dry), adding them into the vessel and mixing them. When this
is done the premix will be pumped or transported by vacuum to the next stage of the
process.
• This machine automates the process of preparation of premix and transferring the
premix into the next stage
• The current machinery is unable to transfer the liquid premix into the next stage,
which has to be done manually and currently this plays a major part in decreasing
the yield.
 Recommendations to increase yields

Total Cost of Machinery Rs. 1,43,60,000

Projected increase in yield of gummy bears ~9-10%
New yield for calcium gummy bears 78.33%
New yield for multivitamin gummy bears 73.33%
New cost for calcium gummy bears Rs. 21.3
New cost for Multivitamin gummy bears Rs. 24.3
Increase In profit per pack of calcium gummy Rs. 3
Increase In profit per pack of multivitamin
Rs. 4
gummy

Manufacturing capacity would be 100Kg per day

Recovery of Capital Spent on machinery in approximately 4 years.

 THE
MEDICARE

To Whom-so-ever it Mav Concern

I am very pleased to recommend Aditya Patel for admission to your University's

Undergraduate Engineering Program. Themis Medicare, founded in 1969, is one of India,s
leading innovative healthcare companies, specializing in Antituberculosis, Antimalarials,
Cardiology, Pain manangement, Anti-infectives, Health and Nutrition supplements. Our
vision is to develop targeted medicines that offer patients and physicians better, more cost
effective healthcare.

Aditya Patel interned with us during the month of May 20i.8 at our subsidiary company Long
lsland Nutritionals Pvt. Ltd (LlN), which is focused on manufacturing nutritional supplement
gummy bears containing calcium, multivitamin and probiotic amongst others.

Aditya Patel worked in our manufacturing unit and performed a host of duties ranging from
helping in the manufacturing process to packaging of products. On completion of his
internship, he pdt together a presentation on ideas to increase the efficiency, reducing
human intervention and cost effective measures,

During his term with us we were most struck by Aditya's focus and work ethic, two
attributes that are uncharacteristic of boys his age. lwas particularly impressed by his
enthusiasm and his interest in trying to learn new things. While he was initially outside of his
comfort zone, as he progressed through his time with us, he not only started grasping more
advanced concepts, but also began approaching us with his own views on the same.

His initiative, hard work and ability to work well in a group environment were all highly
impressive qualities, that l'm sure will see him through any future avenue he chooses to
pursue.

I highly recommend Aditya Patel for admission to your university and wish him
the verv best
in all endeavors,

Reena Patel
DIRECTOR
26/0912018

Themis Medicare Limited

. Corporate ffice : 1rr112, Udyog Nagar,
S. V. Road, Goregaon (W), Mumbai - 400 104. India
. Tel. : 91-22-28747184. Fax:2876 9183 . E-mail : [email protected]
. Regd. Office : Plot No. 69-4, G.t.D.C. Industrial Estate, Vapi, Gujarat.