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Brief Project Report

Toffee Making Plant

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Project Report Toffee Making Plant 

 

Content

Annexure

Process 

2.0

Plant & Machinery

2.1

Fuel/Power/Water

2.2 

Man Power Required

2.3

          Raw Material Required

2.4

                            

 

Process : Annexure 2.0

 

Annexure 2.0

Cooking : There are two methods for cooking the toffee mass, one is open fire cooking in the open pan on any coal or diesel furnace and manual stirring. The quality of product made on this plant is normal. The other method is indirect cooking with steam and automatic stirring with a motorized stirrer. The quality of product made with this method is much superior as compared to the other. Therefore the plant suggested in this report is one which adopts second method.

Steam is generated in the boiler with help of fuel and this boiler is kept away from the cooking or process area. The steam so generated is supplied for the Toffee cooker for cooking. First of all, some ingredients such as milk powder and vegetable fats are mixed in the homogenizer and kept separately. Desired quantity of water is put into the Toffee cooker and the steam is released. When the sugar is dissolved other materials such as liquid glucose and milk paste are added in the cooker. After desired temperature is achieved on the temperature indicator, steam is stopped and material is discharged in the vacuum pan for vacuuming and then on the water circulation cooling table for cooling.

Forming and Wrapping : When the material is cooled down the temperature of approx. 50 degree centigrade. It is folded and put into the batch former. It makes a thick rope of toffee mass which is fed directly into the Cut & Wrap Machine. In this machine the rope first gets rough impression of lining while passing through the first set of sizing rollers and then it gets exact shape in the next set of size rollers. Then the rope is cut by set of toffee cutting knifes and paper is cut by the rotating paper blades and paper is wrapped over the toffee. Which is then and transferred into the rotating chamber which takes it to the twisting fingers where these are twisted from ends and is ejected on to the delivery chute automatically.

Storage and Curing : There are so many types of products that can be made on the Cut & Wrap machine and there is even possibility to Cut & Wrap the Bubble Gum mass (only Cut & Wrap portion can be used for Bubble Gum). However the procedure after cutting and wrapping varies from product to product. For example, chew toffee is immediately ready for the consumer but the brittle and fudge type of products are cured in the heat room for about 24 hours before final packing dispatched

 

Plant & Machinery : Annexure 2.1

 

S.NO.

Machines

Required

1.

Steam boiler capacity 400 lbs. of steam per hour and tested working pressure of 250 lbs./sq. inch with water lifting pump, burner, blower (for oil fired boiler), Fuel tank & other accessories such as safety valves etc.

ONE

2.

Steam jacketed vacuum cum cooking pan approx. production 1000 kgs. per 8 hour shift of with Digital temperature indicator, electric motor, electric control panel equipped with safety devices

ONE

3.

Homogenizer for mixing vegetable fat, milk powder, GMS (Glycerin Mono Stearate) and other materials before charging into the cooker with 2 HP III Phase electric motor and container.

ONE

4.

Cooling Plate with water circulation cooling system

TWO

5

Batch Former capacity 45/90 kgs. per batch with Stainless Steel Rollers, Electronic Reverse, Forward system for roller and motorized lifting.

ONE

6

Rope Sizer five stage with set of gun metal sizing rollers including one set of vertical Pulling head

ONE

7.

Automatic Toffee Cut & Wrap Machine of capacity upto 400 PCs. per minute with Scissor cutting system

ONE

8

Electric control panel with speed regulator, thermostat and safety features with electric motors

ONE

9.

Toffee mass Pulling machine capacity 25 kgs. for pulling of toffee mass

ONE

10.

Storage wooden/plastic trays Approx.

HUNDRED

11. Weighing Scale 200 kgs. capacity

ONE

12. Weighing Scale 25 kgs. capacity

ONE

13 Container 15 kgs. capacity for Sugar/Glucose handling

TEN

14.

20 Lt. bucket for liquids

TWO

 

 

Fuel / Power / Water Requirement : Annexure 2.3

 

Fuel / Power / Water Consumption

S.NO.

Name of Machine

Load

Nos.

Total Load

1.

Steam boiler

 

2 h.p.

One

2 h.p.

2.

Homogenizer

5 h.p.

1.5 h.p.

One

One

2 h.p.

3.

Toffee Cooker

2 h.p

 

One

2 h.p.

4.

Batch Former (Drive)

Lifting

Electric Heater

1 h.p.

1.h.p.

0.5 Kw

One

1 h.p.

5.

Five Stage Rope Sizer 

 

2 h.p.

One

2 h.p.

6.

Toffee Cut & Wrap

3 h.p.

One

3 h.p.

                                                                                       

WATER

1.    About 10 Liters Water required per Minute for Cooling Plate 

        ( This Water can be recirculated after cooling)

2.    About 300 Liters Water per hour for the Boiler even this can be collected in the foam of steam condensates and circulated again

 

           

Fuel Consumption
Oil fired steam boiler consumes approx. 8-10 liters of LDO (Light Diesel Oil) per hour

FUEL

An Oil fired Boiler Consume Apex 8 - 10 Liters of  LDO ( Light Diesel Oil)  per Hour

(This Boiler can operate up to three Toffee Cookers. There is less consumption of fuel for each batch if more then one Cooker is installed 

        

Man Power Required : Annexure 2.4

 

S.NO.

REQUIRED FOR  

NOS.

1.

Boiler and cooling Plate

One

2.

Toffee Cooker

One

3.

Toffee Cut & Wrap Machines

One

4.

Weighing and Dosing

One

5.

Handling Packing & Storage

Three

 

 

RAW MATERIAL REQUIRED

Sugar (Sucrose)

Liquid Glucose

Whole Milk/Skimmed Milk Powder/Condensed Milk

Vegetable fat

Glycerin Mono Stearate (GMS) Flakes

Permitted colours and flavours

Salt

Emulsifiers

Other material as required for relevant products such as Coffee powder is required for Coffee Toffee and Coconut Powder is required for coconut toffee

Packing Paper Rolls