28 February 2011
From Faiza Marketing by Leya
firstly,,during my second month here there are not much that i can share...
my works as i mention before is calculating the moisture content and color of each product, which are:
-Meat Curry
-Fish Curry
-Raja Curry
-Soup
-Beriani
-Turmeric Powder
-Rendang
-Chilli Powder
-Bukhari
-Dalca
and many more
we are using Mettler Toledo Moisture Analyzer to analyze the moisture content and Reflectance Tintometer for color detection. Beside that i must take several important data such as :
- Cold room temperature every morning and before going home
- The sealing temperature for each packaging machine and roaster at 10am and 4pm
- Daily inspection of packaging processes every 3 hours
- Daily inspection of whole processes
This factory using one type of packaging machines which is Vertical Form Fill Seal (VFFS) machines with different types of printing method. Printing is important to print the batch no and also the expired date for every products. There are ribbon printing and also inkjet printing. The ribbon printing is such conventional way instead of inkjet printing which is much faster and high technology.
For Grinding machine this factory use the cylindrical grinder. Its have multiple grinding wheels and sound so loud..hehe (hampir pekak). In this factory there 3 units of grinding machines which are handle by Pakistani (pakistan ni mata biru hehe). I am usually reminding all those Pakistani to stay hygiene and check the mixture trays before putting inside the grinders.
This factory do not apply GMP neither HACCP, so this is quite difficult to train the workers about CCP and others. Although this factory does not have both certificate, but now we are busy doing and implementing the 5S concept from the management department until production area.
Before i forgot, this month we have several visit from the Tabung Haji and also Media Prima. For your information, Faiza Spices supplying tonnes of spices like Dalca and Beriani every year during Hajj season.
And Faiza Rice also supplying and sponsoring rice for 'Bersamamu' tv program. They are entering the Quality Control Lab (my workplace) and ask a lot. From that, it train and manage the way we talk.
I think thats all from me,,
sincerely,
Nurliyana Ismadi
27 February 2011
Content of Internship Report
Salam & Good day,
Below are some guidelines that u can refer in writing a report for your internship session..
Below are some guidelines that u can refer in writing a report for your internship session..
Bahagian
|
Keterangan
|
Bab 1: Pengenalan
|
Pengenalan kepada tempat latihan industri termasuk:-
· Latarbelakang organisasi
· Pengurusan dan Pentadbiran
· Carta organisasi
|
Bab 2: Aktiviti Latihan
|
Pengalaman semasa menjalani latihan industri:-
· Ringkasan aktiviti
· Aliran proses
(contoh : dari bahan mentah hingga menjadi produk atau aktiviti semasa latihan industri)
· Pemasangan, pengujian dan pentauliahan (jika ada)
· Prosedur ujian (jika ada)
· Penyenggaraan
· Sistem kualiti
· Aktiviti R&D
· Prosedur Keselamatan
· Pengurusan jualan atau strategi perniagaan
· Masalah yang dihadapi dan penyelesaian
· Maklumat lain yang berkaitan latihan industri.
|
Bab 3: Cadangan
|
Komen serta cadangan untuk sebarang penambahbaikan kepada organisasi.
|
Bab 4 : Gantt Chart
|
Sekiranya pelajar ditempatkan di bahagian-bahagian yang berlaianan sepanjang tempoh latihan.
|
Dindings Poultry Processing by Siti Shafinas
This is the first post from Dindings Poultry Processing Sdn.Bhd. I hope that the story that I will share with all of you can give some benefits and knowledge to all the readers. I will describe briefly about what I and azrini done here.
A bit on company profile:Dindings Poultry Processing Sdn.Bhd. is situated at Kg. Acheh Industrial Estate in Sitiawan, Perak and launched by Tun Dr. Mahathir Mohamad on 27 August 1990. I am very very sure that most of you out
there (especially who do not live in Perak) does not very familiar and kwon the existence of this company. Some of them also laughed when they heard this company names. Dinding is actually a district or daerah known as Daerah Dinding. However, the name had been changed to Daerah Manjung.
It is one of a subsidiary company of Malayan Flour Mills Berhad. The products are chilled and frozen whole chicken, cut-up parts, deboned meat and further processed products such as sausage, nugget and chicken meatballs. Some of the customers are Macfood, MacDonald, Wendy’s, Giant, Mydin and Domino’s. This company also supply products to Brunei. Other than that, this company also rear their own birds or chicken in their farm located in Segari, Kg. Kayan and Ayer Tawar.
Rules:
- All of the practical students are NOT ALLOWED to go to the further product department (FPD). The same goes to the R&D department.
- We are not allowed to take any pictures inside the production areas except the products pictures. Any forms are also not allowed to be taken outside the company.
Every Monday to Saturday, I and Azrini will come to work as early as 7.30 am. This is all thanks to my mom for driving and sending us here by cars. It tooks about 20 minutes from my house to the company. Then,
we must punch card. Working hours start at 8 am until 5 pm. We go to Zuhur prayers time at around 1.30 pm to 2 pm. There are male and female prayers room. Majority of the workers here are male and
specially imported from Nepal, Bangladesh and some from Myanmar.
On the first day working, we are given company’s uniform, mask, cap and boots. We also been given some briefing. There are 5 practical students here. All are in course food technology.
1 person-UiTM
2 person-UMT
2 person- UniSZA.
We are put under Quality Control and Halal Department. In this section, all the 5 practical students including me, will stay in the meeting room in QC section. If any meeting need to be conducted in this room, we will stay outside the room, where the tables of executive and supersivors are situated.
In addition, at this QC section, the places or ‘office’ for executive, supervisors and clerk are all in one place and there are no dividers among the places. All working positions assembled in one place. The supervisors tables are situated near the entrance door while the executives table are situated at the end of the office.
Mr K.Anuar had divided all of the practical students into five sections. Each of us will be in each section for one week and we will rotate. It started on 10/1/2011. The sections or department that I need to go will start from:
(a) Spin chiller.
(b) Laboratory.
(c) Supply chain.
(d) Halal and evisceration department.
(e) Primary product department.
Most of the executive and supervisors here are still new in their positions and at this department:
(a) Mr. Khidzir Anuar - His age is around late 30. He is the Manager of Halal and Quality Control Department. His wife also worked here as assistant QA manager. Her name is Madam Norenah Salleh.
(b) Mr. Nizam - His age is around mid 30. He starts from working in the poultry farm as an ordinary worker and right now, he had been the Senior Executive for production under QC section.
(c) Miss Azlina Zamri - Born in 1981. She is the QA executive and starts working in this company under this department around Mei last year.
(d) Mr Aslah bin Kamaruddin - Born in 1985. He is the Halal and production executive. Recently got engaged. He also started working here under this company around Mei last year.
CHALLENGES:
1. Since the rotation had already ended, usually I, azrini and also the other practical students will enter the production area by ourselves. We have to be independent and wander around the productions
area and also keep asking the workers or supervisors if there are any work that we can done or if they need any help.
2. Since we are under QC department, basically, all of us will do the work done by the QC personnel. The routine work we usually done these days are:
• Checking the temperature of production area, tunnel freezer area and the products.
• Removing the lung from the rib using knife and chopping board.
• Checking skin, breast and thigh on the moving conveyor belt to make sure there are no foreign materials such as hair or stone or bone found. The breast and thigh usually are skinless and boneless.
BSL BRS = boneless skinless breast. BL BRS = boneless breast.
BL THI = boneless thigh. BSL THI = boneless skinless thigh
3. From office, we will first go through the tunnel freezer area to reach the production area. The temperature inside the production area is extremely cold which is under 13oC. It is very hard and difficult to stay in there for a long time. In addition, the products temperature must be always under 7.2oC to ensure the quality and
freshness of the products.
Just imagine that we have to touch (using gloves) the skin, breast, thigh and rib of temperature under 7.2oC. Usually we can last not more than 2 hours in the production area. Then, we will go out from there
to warm our bodies or return back to the office.
EFFECT: After about one hour in there, sometimes the mucus or what we called as ‘hingus’ will suddenly flow out from your nose. Luckily we wear mask. So it does not obviously shown. The finger nails and finger
toes will turn into pale colour. Other than that, sometimes you might feel cramp and shivering. Even in the night, the effect of the coldness can still be felt. When I want to sleep, I can still feel the coldness and have to cover all my body with the blanket although the fan was not switched on.
SOLUTIONS: I usually wear a thick stocking, an extra clothes and sweater under the company’s uniform. Maybe I need to increase my weight so that I have extra fat that can insulate me from the coldness..
CONCLUSIONS:
There are lots of knowledge and experience can be learned here. I get to see how the birds are processed starting from the receiving of livebirds, the slaughtering process to the production area and until the loading process. Although we could not stand the coldness in the production area, we try our best to stay in there as longer as we can.
I, azrini and ain (from UMT) had been given new task on last Friday (25/2/2011). Actually, this is a group task. We had to do a video clip about the GMP of this company. The video clip will be used as a
briefing material for new workers. Before this, they only show files that contain the GMP materials to do briefing for new workers. Therefore, to do this task, team work is very important. The manager gives us time to do this project for 1 month.
• By the way, on 7/3/2011, the manager said that this company will be visit by 30 students from UiTM of food technology course. So, prof. I think next time in the future maybe the food tech students from UniSZA
can arrange a visit at this company too.
Yours sincerely,
Siti Shafinas Bt Yusri Azhar and on behalf of Azrini Othman.
We Won the Innovative Food Product Development Competition
You all are really Foodtechheroes! On Saturday and Sunday Feb 19-20, our final year students made us proud. They won 2nd place for the innovative food product development competition organised by the MIFT, beating other teams from USM, UMS, UITM and UMT.
The team from UPM scored the fist place and the third place was won by the team from
UMT. The competition was held at the Monash U campus at Bandar Sunway
I would like to congratulate everyone in the team, the final year team. You have shown solid team work and tremendous competitive spirit.
This is the first time we took part in the competition. We also took part in the oratory and food bowl quiz competition. Although we did not win in those categories, it gave a valuable experience to plan for the next competition in two years time.
From Noraini's Cookies by Nadiah Ramlan
It seems like most of the student's excitement during the first 2 weeks of practical had flew away...hehe
maybe they are doing the same thing everyday and the same story will rotating.
In the month of February, Faezah was sent to RND department (sampling the Biskut Raya with Pn Noraini), Mun do marketing in office (cash flow, audit etc), and I was asked to work on spices...
I will share my experience handling the spice premix. The spice production will be run if there is order from other company and personnel. Recently, Tabung Haji Travel ordered our spice premix for their own
brand. So, we are just manufacturing for them, which means, sell the products, not togather with company brand (Spice Paradise).
There are 6 types of premix ordered by Tabung Haji Travel for their TAHA brand. Kari Ikan, Rendang Ayam, Mee Kari, Sambal Tumis and Tomyam
The most painful moment is handling with ingredients like hot chili powder, ginger powder, etc.. mixing 50kg of the spices can make me sneezing more than 20 times a day. Moreover, taking breath in the air surrounded by spices will cause hand and area between nose and mouth become hot (pijar)- not only air taken in, but spices too.
After scaling and mixing, the third operation unit is packaging. The machine used is Horizontal-Form-Fill-Seal (HFFS) machine, but it is quite traditional design. We have to control the insertion of premix into the rotary cup of the machine to avoid too less or too much premix inserted. Besides, we have to weigh again each packed spices. If rejected, the premix is processed again and the foil is wasted.
As the conclusion: The old invention machine require higher labour cost and increase the production time and cost. TQ
maybe they are doing the same thing everyday and the same story will rotating.
In the month of February, Faezah was sent to RND department (sampling the Biskut Raya with Pn Noraini), Mun do marketing in office (cash flow, audit etc), and I was asked to work on spices...
I will share my experience handling the spice premix. The spice production will be run if there is order from other company and personnel. Recently, Tabung Haji Travel ordered our spice premix for their own
brand. So, we are just manufacturing for them, which means, sell the products, not togather with company brand (Spice Paradise).
There are 6 types of premix ordered by Tabung Haji Travel for their TAHA brand. Kari Ikan, Rendang Ayam, Mee Kari, Sambal Tumis and Tomyam
The most painful moment is handling with ingredients like hot chili powder, ginger powder, etc.. mixing 50kg of the spices can make me sneezing more than 20 times a day. Moreover, taking breath in the air surrounded by spices will cause hand and area between nose and mouth become hot (pijar)- not only air taken in, but spices too.
After scaling and mixing, the third operation unit is packaging. The machine used is Horizontal-Form-Fill-Seal (HFFS) machine, but it is quite traditional design. We have to control the insertion of premix into the rotary cup of the machine to avoid too less or too much premix inserted. Besides, we have to weigh again each packed spices. If rejected, the premix is processed again and the foil is wasted.
As the conclusion: The old invention machine require higher labour cost and increase the production time and cost. TQ
15 February 2011
From HPA by Nadhirah
Salam 'alaik.
this is my third post. so this time I would like to share my experience in R&D lab. I've been involving in developing new product since the second day of my industrial training. usually I help my SV (R&D officer) weighing ingredients according to the formulation. and there was a time where they were working on a cereal drink. so the big boss were doing the sensory test (comparing our sample with sample from other brand) and suddenly he said "haa. kamu ambil food tech kan? cuba rasa." the truth is, I had never try any cereal drink my whole life and I'm not interested at all to try it. but as the big boss suruh, so terpaksa la. hehehe. then he ask for my opinion. wahh. and i was wondering whether to be honest or to play safe by saying good
things? the truth is, the taste of the other brand is much more delicious but our product has a better texture. luckily i chose to be honest. haha. and he did agree with my opinion. so friends, if you been asked for your opinion... chose to be honest. XD
last week my SV went to a convention. so i'll be in charge for R&D lab. the first task came when QC officer asked me to prepare 20 samples of our latest product to be sent to the HPA convention. the product consist of more than 10 ingredients. i started weighing at 10.30am and finally finished it at 4.30 pm. talk about tiring!
next few days, i have to develop a new drink product that combines 2 flavour. ALONE. which mean currently I'm doing the work that my SV usually been doing. HA-HA! feel like i'm one of important person here.
the whole week turn to be the buziest week after all. (weighing, changing formulation, find solution, sensory evaluation).talking about developing product, basically I'll prepare product based on a the current product formulation. then i'll change the formulation according to the result from sensory test. in simple word, try and
error. luckily all the staff usually all excited to evaluate the product and give their opinion. so i'll be jotting down thier comments and suggestions. then, i have to find the solution on how to improve it. for example, if most of them comments that the drink has less sweet. but the brix reading is already high. so i may change the
formulation by reducing the amount of sugar and add certain amount of stevia.
sounds like a pro- researcher eh? honestly, it is not that great. you know.. you've been trying so hard all day long just to prepare a brand new product and on the same time you have to accept all the devastating comments like..."apa rasa macam minum air masak je ni?"... "kalau jual kat saya, saya tak beli.". it will break your heart into pieces. haha. trust me. what I can say, this is the toughest part in R&D lab. it is not easy to accept others comments and remain our spirits on the same level.
usually I'll just smile and jot down thier comments. tapi dalam hati... "cerewetnye laa.".."eee.mengada-ngada."
"sabar je la." HAHA. and this process will continue until you finally found a formulation that make them say "sedap!" "terbaik lah." this time you can't even stop yourself from smiling the whole day.
heheheh!
this is my third post. so this time I would like to share my experience in R&D lab. I've been involving in developing new product since the second day of my industrial training. usually I help my SV (R&D officer) weighing ingredients according to the formulation. and there was a time where they were working on a cereal drink. so the big boss were doing the sensory test (comparing our sample with sample from other brand) and suddenly he said "haa. kamu ambil food tech kan? cuba rasa." the truth is, I had never try any cereal drink my whole life and I'm not interested at all to try it. but as the big boss suruh, so terpaksa la. hehehe. then he ask for my opinion. wahh. and i was wondering whether to be honest or to play safe by saying good
things? the truth is, the taste of the other brand is much more delicious but our product has a better texture. luckily i chose to be honest. haha. and he did agree with my opinion. so friends, if you been asked for your opinion... chose to be honest. XD
last week my SV went to a convention. so i'll be in charge for R&D lab. the first task came when QC officer asked me to prepare 20 samples of our latest product to be sent to the HPA convention. the product consist of more than 10 ingredients. i started weighing at 10.30am and finally finished it at 4.30 pm. talk about tiring!
next few days, i have to develop a new drink product that combines 2 flavour. ALONE. which mean currently I'm doing the work that my SV usually been doing. HA-HA! feel like i'm one of important person here.
the whole week turn to be the buziest week after all. (weighing, changing formulation, find solution, sensory evaluation).talking about developing product, basically I'll prepare product based on a the current product formulation. then i'll change the formulation according to the result from sensory test. in simple word, try and
error. luckily all the staff usually all excited to evaluate the product and give their opinion. so i'll be jotting down thier comments and suggestions. then, i have to find the solution on how to improve it. for example, if most of them comments that the drink has less sweet. but the brix reading is already high. so i may change the
formulation by reducing the amount of sugar and add certain amount of stevia.
sounds like a pro- researcher eh? honestly, it is not that great. you know.. you've been trying so hard all day long just to prepare a brand new product and on the same time you have to accept all the devastating comments like..."apa rasa macam minum air masak je ni?"... "kalau jual kat saya, saya tak beli.". it will break your heart into pieces. haha. trust me. what I can say, this is the toughest part in R&D lab. it is not easy to accept others comments and remain our spirits on the same level.
usually I'll just smile and jot down thier comments. tapi dalam hati... "cerewetnye laa.".."eee.mengada-ngada."
"sabar je la." HAHA. and this process will continue until you finally found a formulation that make them say "sedap!" "terbaik lah." this time you can't even stop yourself from smiling the whole day.
heheheh!
From Omcorp by Zul
Assalamualaikum and salam sejahtera,
in this company, since we have four practical students, we have four main tasks that we rotated among ourselves once in two weeks.
the four main tasks are
a) become production supervisor for pasta/spaghetti production.
b) become production supervisor for product that get order from hypermarket chains/restaurants/individual.
c) supervisor for packing and packaging lines
d) administration jobs.
currently, i holding task number (b). and i already going through all the tasks. last week and another last week, i holding position for number (a). i was responsible for everything. from cleanliness, packing, stickers, quality and manage orders from other company.
the task begin when i received fax from the company that request the pasta. and i wrote it down and communicate with production workers on how many needed to produce how many kilograms of pasta. i must checked whether other ingredients enough for the production.
i also dealed with problems that occurred such as over-produced and less-produced.the packing also must be clearly supervised. some packings might be defect and must be checked twice or thrice.in the end of production, i will record everything into a form. and continue with production if new order come.
the process is same if get task for (b).although we have different tasks, we also got common task among us
such preparing GMP documents. We already done Goods Recall Manual ISO 22000, sanitary checklist. SSOP also being done by me with my partner from UPM.
so now this week, i got task for (b). the hardest task. because slight mistakes can cause loss to the company and pushed us to solve any problems that occurred effectively. and the challenge is to minimize any mistakes.
and to overcome all the problems, we must established good communications bonds with other workers although they might less educated from us but they deserved equal respects and they will respect me as the supervisor although i younger than them. (actually i the youngest person in the company...hu hu hu)
treat thems like friends. and i was grateful, when i have big problems regarding last week production, all these workers shows good team work and help me to solve the problems. and in the end we successful in finishing our productions and overcome the problems.
Salam Maulidur Rasul.
in this company, since we have four practical students, we have four main tasks that we rotated among ourselves once in two weeks.
the four main tasks are
a) become production supervisor for pasta/spaghetti production.
b) become production supervisor for product that get order from hypermarket chains/restaurants/individual.
c) supervisor for packing and packaging lines
d) administration jobs.
currently, i holding task number (b). and i already going through all the tasks. last week and another last week, i holding position for number (a). i was responsible for everything. from cleanliness, packing, stickers, quality and manage orders from other company.
the task begin when i received fax from the company that request the pasta. and i wrote it down and communicate with production workers on how many needed to produce how many kilograms of pasta. i must checked whether other ingredients enough for the production.
i also dealed with problems that occurred such as over-produced and less-produced.the packing also must be clearly supervised. some packings might be defect and must be checked twice or thrice.in the end of production, i will record everything into a form. and continue with production if new order come.
the process is same if get task for (b).although we have different tasks, we also got common task among us
such preparing GMP documents. We already done Goods Recall Manual ISO 22000, sanitary checklist. SSOP also being done by me with my partner from UPM.
so now this week, i got task for (b). the hardest task. because slight mistakes can cause loss to the company and pushed us to solve any problems that occurred effectively. and the challenge is to minimize any mistakes.
and to overcome all the problems, we must established good communications bonds with other workers although they might less educated from us but they deserved equal respects and they will respect me as the supervisor although i younger than them. (actually i the youngest person in the company...hu hu hu)
treat thems like friends. and i was grateful, when i have big problems regarding last week production, all these workers shows good team work and help me to solve the problems. and in the end we successful in finishing our productions and overcome the problems.
Salam Maulidur Rasul.
Discussion on viscosity of sauce
Assalamualaikum and good evening. I'm going to share experiments conducted by us. Well, it's better for me to explain background of the experiments. Complainants of customers as well as increasing cases of returned products due to quality deterioration were things that moot the idea for experiments to solve the problem that always occur in sauce production industry.
Deterioration of quality in this experiment refers to low viscosity condition of glass bottle 340ml chili sauce. It easily flows and note that sauce exhibits non-newtonian pseudoplastic behaviour. based on a book titled Understanding Food Science and Technology, written by Peter S. Murano, page 377" Shear thinning fluids are said to exhibit pseudoplastic behaviour. What this means is that the viscosity of the fluid decreases as shear rate increases." So, the problem with the sauce was that even though shear force was not applied,
still the sauce flows easily. This reflects the undesirable quality of sauce. It has very low viscoity.
Based on some company's standard, viscosity at 43dPa.s is the minimum accepted level. Sauce with viscosity lower than that of standard would be rejected from the market products. There are a lot of factors attributed to the deterioration of quality in terms of viscosity, namely storage condition, temperature, cooking
temperature and type of plastic.This writing would discuss the first factor, storage condition. While the
rest factors would be dealt with on the upcoming posts.
After we fill in the sauce into the glass bottle, it is capped, labelled. The bottles arranged on a carton that can place 24 bottles, wrapped and lastly transported into the store. There had been concerns that the way they
are stored in cartons that made heat to stay in the bottles for loner period thus, lowering its viscosity. Starch is the main component for the physical appearance of sauce including its viscosity. Based on our prior knowledge, gel formation concept, starch needs to reach gelation process upon cooling in order to become more solid and firm as well as of high viscosity. So, the sauce bottle that is kept in the store might store more heat, hence it does not reach cooling point causing it to be of higher viscosity.
So, in our experiment, we use two different kind of storage; room and store. Rightly after being packed filled, capped and labelled, the 340ml chili sauce was kept at room temperature and the other one variable used store condition. At the next day, samples are taken. and we found out that sauce kept at room temperature exhibited higher viscosity. To be continued...
_________________________________________________
Reply:
can we add some starch based ingredients to make it more thicken...
_________________________________________________
Reply:
either add starch or give time for the sauce to cool.adding more starch into the ingredient would add more cost.giving time for cooling is also cost as time is money. (unless the production is not concerned about yield as the market demand is still asurplus for them)
_______________________________________________
Reply:
from my experience....the sauce need to be cooled perfectly i think at least 35 degree..because what i found out before bottles sauce make into the cooling tunnel..the headspace is too little..but when they underwent the cooling tunnel...their headspace increase..means viscosity (much higher)..may be the cool water being
used need much lower temp..or the time for the bottles to undergo cooling tunnel need to be longer or lower the speed of conveyor inside the cooling tunnel in order to achieve desired temperature
________________________________________________
Reply:
but it sounds like there's no cooling tunnel .meaning they cool their product relying on the ambient?
________________________________________________
Reply:
Well, you're right. There is no cooling tunnel. We totally rely on the ambient condition for the sauce to be cooled which is not quite effective for it to have higher viscosity. That is one of the main problems. For your information, there are two different modes of 'cooling'.
The first one is by straightly keeping the sauce into the store room after being packed nicely on to pallet. This refers to sauce with glass bottles.
The second mode is that the sauce at the production site for one night before being kept in the store room and this is applied for plastic bottles. And the viscosity problem normally emerged from the sauce of glass bottle.
The problem now is how to provide the cooling process in the store room which is not too cool, with opened air and no controlled ventilation system.
_________________________________________________
Reply:
well then, you all just should apply the method of cooling for sauce in plastic bottles (although you're using glass bottle). cool it over night and bottling is done the next day. it requires time but no additional cost of
adding new ingredients or new machinery. just have a good plan of production and you're set to go! it is cost-free idea, you also could come up with an effective production plan
_________________________________________________
Reply:
cold filling is not a good idea as contamination will occur in the process. The factory should maintain the hot filling technique and solve the viscosity problem in different way. The loss of viscosity is probably due to overcooking or with the quality of thickener.
DISCUSSION TO BE UPDATE...
Deterioration of quality in this experiment refers to low viscosity condition of glass bottle 340ml chili sauce. It easily flows and note that sauce exhibits non-newtonian pseudoplastic behaviour. based on a book titled Understanding Food Science and Technology, written by Peter S. Murano, page 377" Shear thinning fluids are said to exhibit pseudoplastic behaviour. What this means is that the viscosity of the fluid decreases as shear rate increases." So, the problem with the sauce was that even though shear force was not applied,
still the sauce flows easily. This reflects the undesirable quality of sauce. It has very low viscoity.
Based on some company's standard, viscosity at 43dPa.s is the minimum accepted level. Sauce with viscosity lower than that of standard would be rejected from the market products. There are a lot of factors attributed to the deterioration of quality in terms of viscosity, namely storage condition, temperature, cooking
temperature and type of plastic.This writing would discuss the first factor, storage condition. While the
rest factors would be dealt with on the upcoming posts.
After we fill in the sauce into the glass bottle, it is capped, labelled. The bottles arranged on a carton that can place 24 bottles, wrapped and lastly transported into the store. There had been concerns that the way they
are stored in cartons that made heat to stay in the bottles for loner period thus, lowering its viscosity. Starch is the main component for the physical appearance of sauce including its viscosity. Based on our prior knowledge, gel formation concept, starch needs to reach gelation process upon cooling in order to become more solid and firm as well as of high viscosity. So, the sauce bottle that is kept in the store might store more heat, hence it does not reach cooling point causing it to be of higher viscosity.
So, in our experiment, we use two different kind of storage; room and store. Rightly after being packed filled, capped and labelled, the 340ml chili sauce was kept at room temperature and the other one variable used store condition. At the next day, samples are taken. and we found out that sauce kept at room temperature exhibited higher viscosity. To be continued...
_________________________________________________
Reply:
can we add some starch based ingredients to make it more thicken...
_________________________________________________
Reply:
either add starch or give time for the sauce to cool.adding more starch into the ingredient would add more cost.giving time for cooling is also cost as time is money. (unless the production is not concerned about yield as the market demand is still asurplus for them)
_______________________________________________
Reply:
from my experience....the sauce need to be cooled perfectly i think at least 35 degree..because what i found out before bottles sauce make into the cooling tunnel..the headspace is too little..but when they underwent the cooling tunnel...their headspace increase..means viscosity (much higher)..may be the cool water being
used need much lower temp..or the time for the bottles to undergo cooling tunnel need to be longer or lower the speed of conveyor inside the cooling tunnel in order to achieve desired temperature
________________________________________________
Reply:
but it sounds like there's no cooling tunnel .meaning they cool their product relying on the ambient?
________________________________________________
Reply:
Well, you're right. There is no cooling tunnel. We totally rely on the ambient condition for the sauce to be cooled which is not quite effective for it to have higher viscosity. That is one of the main problems. For your information, there are two different modes of 'cooling'.
The first one is by straightly keeping the sauce into the store room after being packed nicely on to pallet. This refers to sauce with glass bottles.
The second mode is that the sauce at the production site for one night before being kept in the store room and this is applied for plastic bottles. And the viscosity problem normally emerged from the sauce of glass bottle.
The problem now is how to provide the cooling process in the store room which is not too cool, with opened air and no controlled ventilation system.
_________________________________________________
Reply:
well then, you all just should apply the method of cooling for sauce in plastic bottles (although you're using glass bottle). cool it over night and bottling is done the next day. it requires time but no additional cost of
adding new ingredients or new machinery. just have a good plan of production and you're set to go! it is cost-free idea, you also could come up with an effective production plan
_________________________________________________
Reply:
cold filling is not a good idea as contamination will occur in the process. The factory should maintain the hot filling technique and solve the viscosity problem in different way. The loss of viscosity is probably due to overcooking or with the quality of thickener.
DISCUSSION TO BE UPDATE...
07 February 2011
Ajinomoto by nurul afiqah
these all mean nothing but HOLIDAY!!! muahaha.
1. the attire that we all (by we all i meant us the 6th sem students. heh.) call the "space suit" is actually known as SMOCK. isn't that just cute? smock! smock! smock! it's just fun to say it. haha. for those who is not familiar with the "space suit" or now known as the smock. heh. it is the attire that most of us get to wear in our factories when entering the high risk processing area (refer to HACCP lecture notes :P)
2. do you know what is a hopper? well we stumble upon it while doing our projects here. i'm not sure whether we missed it during lectures or it's not thought. well after all we don't expect to learn everything in class kan? so why not now go google it and share what you've found what actually is a hopper here at this group? :D clue: machinery related. (konon x nak suap la bulat bulat apa tu hopper. sruh la cari. huih rs cikgu sgt! :P)
3. haa and this was an incident i got into my first week in Aji. was walking through the spray dryer section and the supervisor was going on and on about the spray dryer. then all of the sudden i dropped the cap of my pen onto the floor. if it's in a classroom yeah it's not going to be that big of a deal. but since it's the processing area and not the classroom so yes it's a huge deal.
talking to self: "o'oh! i'm supposed to bring the click click pen and not this kind of pen with the cap. ok nurul afiqah. be strong. here comes the yelling about the pen from the supervisor." (chewah ckp english tu dlm hati. hahaha.)
supervisor: ahah! ni la contoh terbaik. dalam tempat processing x bleh bwk pen mcm ni. lain kali bwk yg mcm ni. (and he gives a big click from his pen.) nasib baik x jatuh dalam machine. kalau x jenoh tu.
fiuh! luckily there's no yelling but that's enough for me to go all around town looking for a click click pen for work. haha. so juniors a must have before going for your practical; a click click pen! :D
4. when people ask you something, don't ever go saying "entah. tak tahu lah." one thing i learnt here is that instead of saying that, say "saya tak pasti." hehehe. it's actually a very neat trick to learn. i discovered this after hearing almost each and every worker here in aji using it. but don't get me wrong. it's not for you to dodge the question. but instead it buys you time to search for an answer. this usually works well when bosses ask you about something and you've got absolutely no idea what he's talking about. hehe.
5. and since i'm all about SOPs now since my project mostly are SOPs for now, i've found these very mind awakening statement. mind awakening ke? haha.
a) "even writing an SOP also has its own SOP."
b) "if not written correctly, SOPs are of limited value. the best written SOPs will fail if they are not followed.
Therefore, the use of SOPs needs to be revised and re-enforced."
for now that's all i've got to share. hope you all get something out of it. insyaallah hope to share more soon. again, happy holiday to all! :)
assalamualaikum.
p/s: prof said we all could go to the mift event the seniors are participating this end of february. there's no need of any payment but with that there'll be no food and drinks for us. but who needs food and drinks, kan diet? hehehe. jom! jom! who wants to go :D
Bumi Hijau by Syimir
Assalamualaikum and good evening.
it's already been past one month since my enrollment in the Bumi Hijau Food Industry as a pratical student.
well, at first, i don't expect too much in learning about technologies as i already know that this is a medium-size company. Nonetheless, there are a lot of things to be uncovered within my this training period. my partner, Feazah whose nickname is Fifa were briefed on the first day. we are placed at six departments, namely storage, production, purchasing, processing, quality and processing department. we were given a timetable indicating the duration for our attachment in each department. and we are not training at
the same department. my first department is storage while my partner is purchase. we are lucky enough to be supervise by the company's quality assurance, freshly graduated from UKM, Miss Ain. She is very much involved in guiding us throughout our industrial training.
in the storage department, I was taught on how to record everything related to storage. goods in and out, delivery order, despatch advice and all sorts of things. I was helping to lift the products as well. sauce products ranging from 6kg up to 15 kg in a carton was what made me feeling exhausted. those products are kept in the store room and are to be delivered to forklift that transport them to the front for the van sale and supplier's orders. this chores were busily handled in the morning. my supervisor said that it was his intention to include me in lifting product as to make it apparent and understandable for me to understand the process.
well, you might be wondering, what was this having to do with quality or food technology. i can see on how storage operators apply FIFO(First In First Out) concept in storage keeping. As well as observing the condition of the store room. To be honest, there was not much to learn when it comes to our course, but i learn more about documentation and storage capacity. This thing can act as an add-value for me in terms of management skill as i learn on how to handle products and raw materials for recording in the storage
department.
Supposedly, I have three weeks in this department. Another event shortened this duration. Bumi Hijau's executive project called us up to assisst to solve a problem were cases of melted or of low viscosity chili sauces in the market. We were required to conduct experiments to determine the factors for this event. What will happen? I'll continue on subsequent posts afterwards.
it's already been past one month since my enrollment in the Bumi Hijau Food Industry as a pratical student.
well, at first, i don't expect too much in learning about technologies as i already know that this is a medium-size company. Nonetheless, there are a lot of things to be uncovered within my this training period. my partner, Feazah whose nickname is Fifa were briefed on the first day. we are placed at six departments, namely storage, production, purchasing, processing, quality and processing department. we were given a timetable indicating the duration for our attachment in each department. and we are not training at
the same department. my first department is storage while my partner is purchase. we are lucky enough to be supervise by the company's quality assurance, freshly graduated from UKM, Miss Ain. She is very much involved in guiding us throughout our industrial training.
in the storage department, I was taught on how to record everything related to storage. goods in and out, delivery order, despatch advice and all sorts of things. I was helping to lift the products as well. sauce products ranging from 6kg up to 15 kg in a carton was what made me feeling exhausted. those products are kept in the store room and are to be delivered to forklift that transport them to the front for the van sale and supplier's orders. this chores were busily handled in the morning. my supervisor said that it was his intention to include me in lifting product as to make it apparent and understandable for me to understand the process.
well, you might be wondering, what was this having to do with quality or food technology. i can see on how storage operators apply FIFO(First In First Out) concept in storage keeping. As well as observing the condition of the store room. To be honest, there was not much to learn when it comes to our course, but i learn more about documentation and storage capacity. This thing can act as an add-value for me in terms of management skill as i learn on how to handle products and raw materials for recording in the storage
department.
Supposedly, I have three weeks in this department. Another event shortened this duration. Bumi Hijau's executive project called us up to assisst to solve a problem were cases of melted or of low viscosity chili sauces in the market. We were required to conduct experiments to determine the factors for this event. What will happen? I'll continue on subsequent posts afterwards.
Dept of Chemistry by Tarmizi
The first analysis was doing is Determination Organophosporus (OP) in Fruits and Vegetables QuEChERS Method. This experiment is doing to identify the level of OP that use in the fruits/vegetables by running
the extract of sample using Gas Chromatography (GC). Then, the second analysis was doing is Determination of the Aflatoxin B and G in the Peanuts based product. There are eight sample that must be to extract such as kacang tumbuk, peanut butter, kacang manis, pau kacang and others including two spiking sample that must spike with Afla BG standard 1ppm and 5 ppm which must be running using the Fluorescence Detector High Perfomance Liquid Chromatography (HPLC). Based on the Food Act 1983, the maximum level that allowed in microgram per kilogram for the peanuts (Alfatoxin B and G) is 15, milk (Alfatoxin M1) is 0.5 and others finish product that have mycotoxins is 5.
My supervisor, Mr. Nor Shifa Bin Shuib give me the two project that I must have done during my industrial training. The first project is “Determination of Deoxynivalenol (DON) in the Raw Wheat, Wheat Flour
and Wheat Based Products. The selected molds that produce DON is Fusarium graminearium and the food susceptible to contamination are wheat, corn, barley, malted barley and oat. When the people consume
the high level of this DON toxin the effect to the health is damage to digestive tract, bone marrow, spleen, weight loss, vomiting and fees refusal.
So, the preparation to this project was starting from week two until week six. Before analyze DON by using the Ultra-Violet Detector HPLC, there are some procedure that must be follow. Firstly, the Ultra-
Violet Spectrophotometer must be calibrating to determine the Correction Factor (CF) in the range 0.95-1.05. When measuring of CF in that range, the calibration of DON standard was doing to identify the
absorbance and maximum wavelength (highest peak) which using in the set up the wavelength at the UV Detector HPLC. The absorbance can be use to measure the concentration of the DON standard before diluted with Acetonitrile (ACN) until 10ppm and 20ppm.
The samples that I was collected are wheat grain, barley, oat, yellow noodles, instant noodle, and wheat flour. There are two procedures to determine the DON in food which are extraction and the Immunoaffinity
Column (IAC). For the extraction method, the 25g sample was added with the 5 g Polyethylene Glycol (PEG) and 100ml purified water. The mixture was blended for 1 minute and filter via the filter paper and
then, via the micro fiber filters paper. For the IAC, the 2ml of extract sample was pipette into the column and wash with 5ml purified water. The excess water removes and pushes the air until the column dry. Then, 1ml of HPLC Grade Methanol was pipette into the column to collect elute into the vial. The vial was drying using the nitrogen gas and pipette the 1 ml Injection Solvent [Water (9): ACN (1)] into the vial, ad then shake the vial homogenize.
Before run the sample, the DON standard must be prepared first. The 0.5ml of 20ppm DON standard is pipette into vial and dry using the nitrogen. Then, 1 ml of IS was added into vial and shake completely.
The DON standard is ready to run and determine the peak of the standard. After determine the peak of DON standard, the vial of food samples can be run using the UV detector HPLC. The retention time for
DON standard is at 5.24 minutes. From the foods samples that run, the entire samples show no peak (negative) at this retention time. I assume that the DON in the sample are absent or present in little
amount that cannot be detected using the HPLC because no sensitive. There are some precaution step protection equipment that must be follow up because there are handling the solvent and chemical compound
when doing the analysis such as wearing the gloves, mask, use the fume cupboard and others.
At here, I was learned the application of the HPLC, UV Spectrophotometer and others equipments that used for the analysis. The all staff at this department is nice and friendly (especially girl..huhu) to teach me the new and the procedure that I didn’t know to do. There are no foreign workers especially “abg la”…just have the sweet black skin people (kulit hitam manis) because the area of “anak mami”…huhu…
Please wait for the next post in my second project..=D
Retort Keropok Lekor by Zulhilmi
By Zulhilmi
Assalamualaikum dan salam sejahtera,
1. firstly, do you remember Seminar teknologi makanan that being held
around april 2010 when our Prof adjung, Dr. Nasir and Dr John?
2. i remember dr. nasir said that now in food technology especially in
EU are pursuing to create foods that free from any preservatives and
the demand for that kind of foods will keep increase.
3. in case, for example, retort sausage or RTE sausages that free from
any preservatives due to treatment from HTST treatment. this cause the
sausage free from its main preservatives such as nitrite that can
binds with amino acids in meat at high temperature to form nitrosamine
that carcinogenic to human.
3. when i practical here, i still keep exploring how they want to
produce retort meat-based products and dubbed as the first company in
Malaysia doing that with halal.
4. then, i further my reading on this book :
http://books.google.com.my/books?id=_6cQ-dFuzGIC&pg=PA129&lpg=PA129&d...
5. Prof Abdullah once told us that CCP for usual food production is
just in minimal amounts and even in this company they just have 2
CCPs. but according to this book...the whole process to make retort
meat have 25 CCPs !
6. the retort process can be done by using autoclaves or retort like
in our makmal FTM.
7. MY POINT IS, the industry are competing to produce retort sausages
made from beef, chicken and so on. this new product will no need to
refrigerated and can be taken from the shelf like the chocolates and
eat directly without need for cooking. simple and convenience. that
the food tech all about.
8. however, in terengganu, we have Keropok lekor. and i think why not
the fish meat can undergoes retort process, and produce retort keropok
lekor product , where can be stored for months without
refrigeration,and can be put on the shelf and can be consume
immediately.
9. i guess the technology is still rare in Malaysia, and i might be
lucky to see how the Japanese done the retort-based product with their
own technology.
11. the retort-based keropok lekor also can be brought as space foods.
Sheikh Muszaphar can try it i guess...
12. like this company motto, Malaysian Halal with Japanese
Innovations.
Respond by Prof Che Abdullah :
The technology is already available in Japan. I visited a factory in
Osaka in 1987 producing shelf-stable meat sausages. The product is
also popular in China now.
By Zulhilmi :
yes prof..pn mazidah already say the same thing..the sausages that being
produced in china and japan...except they are not halal...thats why they
want to bring the technology to Malaysia..but wow, 1987 they already
produced it....we still lack behind..at least for a decade..2 weeks ago we
also got in our hands some of these products made from indonesia. now
indonesia already produced the same thing...this kind of retort sausages is
one of the products that create huge attractiveness during mihas 2010..
Dept of Chemistry by Farhana
It’s a bit late to share my experience in this group, but I’ll continue updating it after this. ^-^
Doing practical in DOC, for sure it is 100% research-oriented. Every branch in Malaysia has at least 8 labs. But in Penang, only four will carry out food-related analysis (Food Lab, Mycotoxin Lab, IKTD Lab, &
Microbiology Lab).
Food Section provides three main services;
1) Additives & contaminants (major)
2) Standards & specifications (nutrition labeling)
3) Pesticide residue.
But for now, pesticide analysis already is in charge of Mycotoxin Lab. Halal analysis not offered here. If there are any Halal-related cases, it will be sent to HQ (Petaling Jaya) for DNA analysis. Some urgent
cases like foreign matters analysis (especially those involve pest like cockroach) or melamine cases also will be referred straight to HQ as it equipped with better technique and equipment.
These are brief list of my activities in DOC through January
(Week1 – Week4):
1) Learn safety rules & equipment
I have been taught to choose suitable PPE (Personal Protective Equipment) according to experiment. For common analysis, we can use latex gloves and mask. But when handling hazardous chemical, face
shield, glass/goggle and respirator are applied. Nitrile gloves and carbon-free mask even recommended. Lab workers also must know how to operate and check efficiency of emergency response equipment (eye-wash
station, shower, fire blanket).
2) Learn basic handling of apparatus & equipment
Although it looks simple, but not all peoples know how to use common apparatus in correct way, include me. Sometimes due to inadequate equipment, we don’t have the opportunity to handle the apparatus in
lab session. So, I do recommend our faculty to do basic lab skill workshop (practically) for our junior (maybe senior also…).
3) Compile most of test method manual used in DOC
For DOC, each method is continually validated and improved. Modification will be done by HQ if there is any better analytical method.
4) Be involved in handling of food sample sent by client
• Important client: Health Department, army, private company
• Food sample registered and described in sample forms and worksheet
• Case determined formal/informal or urgent/TUL/common
• Unused sample stored in storage room (in cabinet/oven/freezer/ chiller)
• After analysis, calculation and result compiled with worksheet
• Status of case determined (compiled or not)
• Duplicate test done for non-compiled case
• Sample used disposed and result sent to client (For army cases, result:30 days after sample sent, other cases: 50 days)
5) Analysis of heavy metal by using AAS
This is my major task in Food lab, but still focusing on dried form sample. Previously, the analysis is done by Mr.Ramli, but he just transferred to HQ. Most food sample is tested for presence of Pb and Cd by using Avanta software. Examples of common sample received are sardines in tomato sauce, milk powder, MSG, dried squid, and energy drink.
From 15 samples, only one (dried seaweed) is not complied in term of its cadmium level. Duplicate test must be carried out in this case. For mercury analysis in food, mercury analyzer is used as alternative. AAS only used for non-food analysis of mercury. Until now, Food Lab has remaining 52 samples to be analyzed with AAS.
6) Analysis of foreign matter by using FTIR
The sample is tamarind paste, which contaminated with plastic and hair. By using OMNIC software, absorbance curve are obtained (FTIR is the simplest equipment I ever handled). After ATR and baseline
correction done, result compared with library database. The plastic detected as polyethylene and polypropylene. But the hair shown result for wheat gluten flour. So, it was sent to Criminalistic lab for
better analysis (also to check whether it is animal or human hair)
7) Research Project : Determination of Boric Acid in Noodles by using UV- spectrophotometer
For this project, alcoholic turmeric extract will be used as indicator in qualitative test. If cherry-red color formed, the sample can be preceded to quantitative test by using UV-spectrophotometer. But I
still stuck in the calibration of Boron standard solution. Personally, I do think it such a difficult project. I heard that previous practical student also got this project, give up and change her research last minute (she even crying, which make me want to do it too … T-T). Dealing with extra-hazardous (everything is highly
concentrated), plus highly unstable chemicals, we already taken maximum safety precaution. Yet the result of standard graph remained fluctuated (I already repeated it 7X). I will continue trying, and maybe request another research project at the same time as alternative. But handling 500ml concentrated H2SO4 by my own in preparation of Carmine reagent is such a great experience (shaking so much, but feel like newly-born after do that...hehe).
My Plan for February activities
Continue research project of boric acid
Planning for alternative research project (any suggestion?)
Carry out wet sample analysis wit AAS
Learn operation of GC (determination of % alcohol in wine, rum, gin, & vodka)
Doing practical in DOC, for sure it is 100% research-oriented. Every branch in Malaysia has at least 8 labs. But in Penang, only four will carry out food-related analysis (Food Lab, Mycotoxin Lab, IKTD Lab, &
Microbiology Lab).
Food Section provides three main services;
1) Additives & contaminants (major)
2) Standards & specifications (nutrition labeling)
3) Pesticide residue.
But for now, pesticide analysis already is in charge of Mycotoxin Lab. Halal analysis not offered here. If there are any Halal-related cases, it will be sent to HQ (Petaling Jaya) for DNA analysis. Some urgent
cases like foreign matters analysis (especially those involve pest like cockroach) or melamine cases also will be referred straight to HQ as it equipped with better technique and equipment.
These are brief list of my activities in DOC through January
(Week1 – Week4):
1) Learn safety rules & equipment
I have been taught to choose suitable PPE (Personal Protective Equipment) according to experiment. For common analysis, we can use latex gloves and mask. But when handling hazardous chemical, face
shield, glass/goggle and respirator are applied. Nitrile gloves and carbon-free mask even recommended. Lab workers also must know how to operate and check efficiency of emergency response equipment (eye-wash
station, shower, fire blanket).
2) Learn basic handling of apparatus & equipment
Although it looks simple, but not all peoples know how to use common apparatus in correct way, include me. Sometimes due to inadequate equipment, we don’t have the opportunity to handle the apparatus in
lab session. So, I do recommend our faculty to do basic lab skill workshop (practically) for our junior (maybe senior also…).
3) Compile most of test method manual used in DOC
For DOC, each method is continually validated and improved. Modification will be done by HQ if there is any better analytical method.
4) Be involved in handling of food sample sent by client
• Important client: Health Department, army, private company
• Food sample registered and described in sample forms and worksheet
• Case determined formal/informal or urgent/TUL/common
• Unused sample stored in storage room (in cabinet/oven/freezer/ chiller)
• After analysis, calculation and result compiled with worksheet
• Status of case determined (compiled or not)
• Duplicate test done for non-compiled case
• Sample used disposed and result sent to client (For army cases, result:30 days after sample sent, other cases: 50 days)
5) Analysis of heavy metal by using AAS
This is my major task in Food lab, but still focusing on dried form sample. Previously, the analysis is done by Mr.Ramli, but he just transferred to HQ. Most food sample is tested for presence of Pb and Cd by using Avanta software. Examples of common sample received are sardines in tomato sauce, milk powder, MSG, dried squid, and energy drink.
From 15 samples, only one (dried seaweed) is not complied in term of its cadmium level. Duplicate test must be carried out in this case. For mercury analysis in food, mercury analyzer is used as alternative. AAS only used for non-food analysis of mercury. Until now, Food Lab has remaining 52 samples to be analyzed with AAS.
6) Analysis of foreign matter by using FTIR
The sample is tamarind paste, which contaminated with plastic and hair. By using OMNIC software, absorbance curve are obtained (FTIR is the simplest equipment I ever handled). After ATR and baseline
correction done, result compared with library database. The plastic detected as polyethylene and polypropylene. But the hair shown result for wheat gluten flour. So, it was sent to Criminalistic lab for
better analysis (also to check whether it is animal or human hair)
7) Research Project : Determination of Boric Acid in Noodles by using UV- spectrophotometer
For this project, alcoholic turmeric extract will be used as indicator in qualitative test. If cherry-red color formed, the sample can be preceded to quantitative test by using UV-spectrophotometer. But I
still stuck in the calibration of Boron standard solution. Personally, I do think it such a difficult project. I heard that previous practical student also got this project, give up and change her research last minute (she even crying, which make me want to do it too … T-T). Dealing with extra-hazardous (everything is highly
concentrated), plus highly unstable chemicals, we already taken maximum safety precaution. Yet the result of standard graph remained fluctuated (I already repeated it 7X). I will continue trying, and maybe request another research project at the same time as alternative. But handling 500ml concentrated H2SO4 by my own in preparation of Carmine reagent is such a great experience (shaking so much, but feel like newly-born after do that...hehe).
My Plan for February activities
Continue research project of boric acid
Planning for alternative research project (any suggestion?)
Carry out wet sample analysis wit AAS
Learn operation of GC (determination of % alcohol in wine, rum, gin, & vodka)
Deligateaux from Fleura May
My internship in DELIGATEAUX (M) SDN BHD had already been more than 1 month and there are plenty of things that I would like to share with all of you which I have no idea where should I begin with. But I promise that I will jot down my experience here as simple and clear as I could so that everyone can understand.
Well at first, I don’t expect that I would enjoy having my internship in DELIGATEAUX because my first impression on this company was that it was a small company and I expected that I couldn’t learn much here.
Back then, I was also thinking of how this company can have such a broad market like what had been described from the website? I gotta find out.
After one month working in this company, the experience that I get proven me that my earlier thoughts were wrong. I cannot simply judge a company by its surface. I truly feel that I’m extremely blessed to have my internship in DELIGATEAUX as the staffs here are very generous to answer all the questions and my curious thoughts. They are hilarious and freaking funny at times too! XD It is really great here and I recommend Prof. sending more students here in the future. =) Somehow, I feel like working life seem to be easier than
studying. o_O No idea where that come from. Hihi! =)
Alright. There are 9 practical students here which are 4 students from UNISZA, 3 students from UMT and another 2 students from UITM. For the UITM students, both of them has been enroll into this company a month earlier than the rest of us.
On the first day of our internship, we were assisted by Mr. Fuad, the assistant marketing manager of the
company. He gave a short business presentation of the company and explains to us briefly on what the company was all about. He also brought us all into the factory to have a look. We were then met the general manager of the company, Miss Roslinda Abu where she shares her experiences with us.
For your information, DELIGATEAUX has its own Café which is known as DUDUK CAFÉ in Solaris, Dutamas. Mr. Fuad, had divided 7 of us into 2 groups to work in DUDUK CAFÉ in Solaris and in
DELIGATEAUX office and factory in Bandar Pinggiran Subang. The first group was Haniza, Dayah Mazlan and Izzati. They are the ones that start their practical in DUDUK CAFÉ for the first 7 weeks. Meanwhile
the other 3 UMT students and I will be going to the Café after the 7th week.
In DELIGATEAUX also, we are not assigned to any department since the general manager mention that she would like us to learn about the company as a whole. So the trainees will have the chance to explore
every part of the company. Here, we were not assigned to any supervisor. Everyone will supervise you. So it’s good to have many sifu =) In Bandar pinggiran Subang, my job wasn’t entirely on factory alone. I also work in the office as well. Throughout these days, there are many things that I learn.
In the factory, the trainees were taught on how to make many different types of cakes, how to handle the machine, how to do the packaging for DELIGATEAUX product, as well as simple things like mopping the floor. Don’t be surprise someday if anyone found out that some students nowadays may know how to study but not knowing how to sweep or mop the floor. It is just an example. Part of learning experience. =)
During this period, I also learn about R & D and to be honest as I observed, they did not have a proper way to do R & D because I noted that in this factory, how they did the R & D was somebody will just simply jot down the list of ingredients that they need, let say…morn flake cake. Then they will choose on which method they’re using for example fruit cake method or pound cake method or any other method of doing it. That's it. I think they suppose to have a proper procedure for that.
Meanwhile for the sensory test, it is different from what we have done in UNISZA. As far as I know and from what I observed, the sensory test was done among the DELIGATEAUX staff only where there were only limited comments that we can give. They should send more of the sample to DUDUK CAFÉ since there they can get an easy access to the customers and it will give a better feedback too.
Meanwhile in office, I was not only supervised by Miss Roslinda, but other staffs as well. I learn a lot from them such as Kak Ina and Kak Azian, they taught me on how to record for warehouse, how to count the
boxes and stickers of each product, as well as filing and arranging the invoices and delivery order into files. It was quite tiring sometimes because if there were even a slight mistake, I have to re-do the whole process all over again.
Anyway, I truly enjoy my work very much. Besides that, I was also taught by Kak Azian on how to count
sales. It much more simple than what I’ve been learning in account class back then =P XD She even gave me a task that was to count the company sales for 2010. It took me 2 days to complete the task since I have go through all the marketing files one by one and type each of them into the computer. Before I could handle the final copy to her, I have to re-check them all over again. Meanwhile Miss Roslinda, she taught me a lot for the past few weeks. She also assign me with lots of tasks. First task that she gave me was preparing power point presentation for Deja Vuu which is a new DELIGATEAUX Frozen Cakes. She also assign me to update the company facebook weekly, doing blogs for the company as a way to promote its product and the last task that she given to me before she resign on 31st January 2011 was making product quotation for DELIGATEAUX both in MYR and USD. Although she was resigned from the company, she told that she would still keep an eye on the company progress and will come once in a while whenever she has the time. Sad =( she was a good manager and I like her.
About 2 weeks ago, DELIGATEAUX also has its annual dinner. It was held on 28th January 2011 which was few days before Miss Roslinda resigned. It was the first annual dinner for DELIGATEAUX after 8 years they had been operating. The staffs also have been preparing for the annual dinner over the pass few weeks. From this annual dinner, it taught me a lot of things such as how we can get sponsors for the dinner, writing a proper letter to get sponsor from the suppliers and I was given the chance to communicate with the
suppliers to ask for sponsors. It is funny communicating with them. I got the chance to see the different behavior and character that they had. =) We managed to get quite a lot of fund from suppliers and
during that weekend also, using the remaining fund that was leftover from the annual dinner, the company giving us a treat to wet world! \
(^.^)/ It is a blast to be here and I treasure every moment. But no matter how enjoy I’m here, how much fun leaning here, I do miss UNISZA. Hopefully our sharing in this blog will benefit everybody.
That’s all from me today. There are more things that I would like to share but I have to end it here today. Bye! ^_-
p/s: I’m still on my Chinese New Year break until this Wednesday.
Actually, I only apply leave for 3 days but instead of giving me 3days
leave, they giving me 1 week. o_O I love this company =D
Regards,
Fleura Siew
26 January 2011
National Online Quiz 5
We in the faculty pleased to welcome a participation from the foodtecheroes in or outside the campus to join National Online Quiz 5....Go ! Go! Beat them and be the winner!
Wish u all the best!
Rikevita by nurul hidayah mohd noor
as for this week, i have to change with Shela where, I have to run
test for EMA product and Shela have to run test for EP product.
this is to make sure that we can do all test if they asked to.
so, this week started with 'dup dap dup dap' as i do not familiar with
all the test for EMA product as Shela does..
i have to refer to the note book all the time...
but, alhamdulillah,they guided me well...
for EMA product, the test involve are chemical test...
so, the titration is a must!!
for the first day, i have to test 17 samples for the acid value and
GPC...
from that practices, i've got more familiar with the acid value test
and GPC..
today, there is a training about GC from the supplier...
so, we have to attend the 'lecture' about GC for almost 3 hour!!
it's quite sleepy but we learned new things here...
but for me, en tajul's lecture for GC is better...haha..
they also provide us with the slide show for reference...
the 'mukadimah' from the supplier is quite frightening...
'u all mesti da familiar dgn GC ni, sbb utk "instrumentation", mesti
ade blaja psl chromatography ni utk 1 sem'
hah??
for ur information, all staff in QC do not have any basic in food and
mostly are graduated in chemical industry courses...
so, they are very expert in chemistry test and we can learn a lot from
them...
as the theory sessions ends, the supplier showed us how to run sample
using GC....
but there are some problem occur..
so, he will continue it tomorrow together with an exam!!
13 subjective questions!!
so, we have to study the slide show for tomorrow's exam...
i will end it here...
do pray for us!!
assalamualaikum....
24 January 2011
Ajinomoto by nurul afiqah
our week 2 here in Aji is less in terms of action and adventure if
compared to week 1. hehe. but never the less, we learn! learn! learn!
there's more sitting in the office doing our mini projects rather than
wondering around Aji looking for new things to look at (though we
pretty much covered the ground in the 1st week. i think. heh.) but
alhamdulillah all is well. :)
the highlight of the week i must say is the cooking class that we compared to week 1. hehe. but never the less, we learn! learn! learn!
there's more sitting in the office doing our mini projects rather than
wondering around Aji looking for new things to look at (though we
pretty much covered the ground in the 1st week. i think. heh.) but
alhamdulillah all is well. :)
participate here at Aji. yes! cooking class ladies and gentlemen!
believe it! we now can cook! i have a free apron to prove it. Aji
bagi. ngahaha. padahal gabra masa orang suruh tumis bawang jangan
cakaplah :P the cooking class was on friday after office hours. hehe.
stay back siap hah! ati was in team Seri Aji and i was Tumix. (heh.
baru terfikir. patut buat chant macam english week untuk team. "TEAM
TUMIX MASAK SEDAP! KORG AIR LIUR LELEH SILA LAP!" hahaha.)
ok. enough silly talk. heh. lets move on to serious business. :D
what i've learnt for the past week is that we should be friendly. the
key word for today is FRIENDLY ye. hehe. if we're too shy, do try. get
involve as many things at once as possible. whatever activity there's
to join, go for it! :D just imagine if you're a manager, a friendly
one. your workers working under your management would be pleasant if
you're around. wouldn't that be a great thing? instead of them praying
for you to get into a car accident and die? haha. we need to learn how
to communicate with different people. old, young, experienced, because
the industry doesn't only consist of youth like we are so so so used
to in class.
in class, when there's group work, it tests us how to communicate with
the group members. which have similar background as we do. but what
i've faced during these 2 weeks of practical the scenario is far
beyond from what we have in class. so, taking this opportunity to
learn how to be friendly would be a wise choice. because if we do
screw up, we're still students and not the manager just yet. :)
so apa tunggu lagi? on 'FRIENDLY' dan hantar ke 32999. ngehe. by the
way, asking questions about the company is only a part of being
friendly. tak kan nak tanya pasal company tiap tiap kali bukak mulut
untuk 4 bulan kan? but don't go around gossiping with the factory
operators pulak. :P pandai pandai lah kan. alah. dalam bahasa canggih,
friendly ni kira 'soft skill' lah. hehehe.
and also through this post i would like to wish all the LI students,
HAPPY THIRD WEEK LI ANNIVERSARY :P hang in there weyh! hehe. and happy
thaipusam to all. holiday! holiday! hehe. hope to share more soon.
assalamualaikum. :)
Noraini's Cookies by nadiahramlan
Emm..sorry for the lateness, reporting on our activities in NORAINI
COOKIES..
Firstly, NORAINI COOKIES was located in industrial area..so there are
a loooooooot of bangla and indonesian here.. besides, most of the
factories here are engineering-based factory..it is hard to find women
in this area except in this factory... for the first time we were
quite scare being "swiit swiitt" by abangla but after 2 weeks : "alah
bisa tegal biasa".
There are 9 practical student here, 3 from UNISZA (4 months), 3 from
UPM (6 months), 3 from UITM (4 month)...
Basically, we were divided into group for RND, production, and
marketing (stay in the office). But, for these 2 weeks, mun, faizah
and I just work at production area. All we did were making, packaging,
the spices and biscuits..and cleaning too.. before that, NORAINI
COOKIES also produce frozen food (sardine roll, curry puff), keropok
losong, spices, and biscuits. In simple words, we did what the other
workers (most of them are indonesians) did. And, we worked from monday
to saturday from 9am till 6pm. The OT is 6pm to 7pm.
Our work is like in bakery lab, no bench and handling the bread which just like baby
(as Mr Aziz said). Actually the bread is to be turned into biscuits
and baked twice. The biscuits (sugar biscuits and garlic biscuits) are
quite new product here. The garlic biscuits is new in market and quite
delicious. It was Pn Noraini's RND. Till now, we never made the main
product of NORAINI COOIKES which is the famous cookies (7 types of
flavour) iteslf.
Region Industries Sdn. Bhd. (Under KFC Holdings) by Shazwan
Region Food Industries Sdn. Bhd. (Under KFC Holdings)
Hye everyone..salam semua
Seems that many of my friends already shared their valuable thoughts
and experiences.. So may I join you guyz here?? ngeh3 Since I never
post any of my experiences yet for the past 2 weeks of my
practical..so here we go..I’ll summarize up what have I did and what
have I learnt so far..
Ok..i request to have my practical under KFC Holdings and was hoping
they will send me to Ayamas Corp..but unfortunately they posted me to
Region Industries Sdn Bhd (RFI). But no regret..i still enjoy most of
my time doing my practical here! Ironically Ayamas Corp is just
adjacent to RFI T_T it so near..kalo jalan kaki pun peluh tak sempat
nak keluar sebab dekat sangat haha
Hurm...how am I going to start..its so much to tell!! Fine..Let start
with this…to Prof Abdullah your ex-student Mr. Murat Hanafiah kirim
salam..im quiet surprise he is your ex student..anak didik prof
nampaknya ada di seluruh Malaysia haha..fyi he is our senior
production manager..a very important person in RFI..and Mr Murat is my
supervisor for this time being since our production executive had
resigned last November.
Owh ya..according to the formal letter given by KFC Holding..it is
clearly stated that they will attach me at production department..so
sadly I’m not much exposed in QC or R&D department..but I try to sneak
in to those departments and try to learn something! ngeh3 so far I’ve
asked QC seniors or even QC supervisors to know a little bit regarding
things that being conducted by QC department..*for example I watched
and learnt about CIP in mayonnaise station, asking what roles of QCA
at Bottling station and Hassia Station and many more. *Did you guyz
noticed that QCA doesn’t required any related food certification??
Just based on SPM, you can apply for the post of QCA...i thought this
post require at least diploma certificates in Food studies..but I
guess I was wrong…
So since my territory is only Production department…then I was
assigned to fully master this department in a period of a week..This
factory is quiet huge and even within two weeks…I still have many
questions in my head..To make this task even more interesting..i need
to explore this department by myself..ok..that quiet tough! Ahaha.
Based on what have I read on others comments on Facebook, many of my
friends need to do all the industrial works..in contrast, saya pula
tak berpeluang nak rasa pengalaman macam tu because major productions
flow are conducted by automatic machines..kalau ada yang perlukan man
power pun..pekerja asing dah cukup banyak dah..so I just observe and
observe..*pernah sekali saya cuba nak tolong buat kerja..tapi rasa
kelakar plak sebab macam berebut kerja dengan mat bangla tu..ahhah may
be sebab dia takut kene marah dengan line leader kalau tak buat kerja
kot..heheh
My first week is mainly knowing who is in charge for every machines
and stations..There are several line leaders here..i need to know them
first..so that they can teach me anything that I need to
know..Here..public relations, confidence and being friendly are very
crucial..I learnt to be more proactive..dan pada masa yang sama saya
perlu ringan mulut untuk bertanya..kalau tak bertanya..then I learn
nothing..so kena buang rasa malu tu jauh-jauh..then lebarkan senyuman
anda!! Tanya khabar pekerja-pekerja tu..barulah bila dia nak share
ilmu pun tak rasa keberatan sangat ngee~
Owh I almost forget to tell you guyz..RFI basically known for
products with the name of LIFE..from what I’ve learned..50% of the
products will be used by KFC and Pizza Huts Restaurants..30% for
exports and remaining will be sent to local markets. Usually products
will be export to Singapore, Vietnam (KFC), Bangladesh, Australia, UAE
and many others.
There are numerous products being produced here. Their major products
are chili and tomato sauces (sachet/bottles/ pouches), mayonnaise such
as 1000 island, mayo spread, salad mayo etc.. ( use in KFC’s burgers
and coleslaw, Pizza Hut’s Salad dressing) , spoonable jars such as tom
yam paste, chicken curry, fried chili. RFI also produce soups powder
such as chicken and mushroom soup (for Pizza Hut restaurants) ..and im
telling you guyz the list is unstoppable!! Haha too much to tell ..
This factory operate 24 hours non-stop..
If you guyz noticed at any KFC Restaurants in big cities especially in
Klang Valley, those restaurants are no longer using bottle sauces
anymore..Nowadays, they used sauce dispenser same like what McDonalds
Restaurants had used. Here, the machine used to produce (sauce
dispenser) is called as on-pack machine and the sauces are packed in
pouch with weighed of 3kg. It’s pretty new actually. According to Mr
Murat, this sauce dispenser (3kg pouch) will be the main product as
many KFC restaurants will use it soon. *agaknya KFC rugi kot sebab
ramai yang curi bawak balik rumah botol sos tu! haha sebab tu KFC
gantikan dengan sauce dispenser.
RFI has a new Mayo Plant and insyallah.. will be fully operate after
Chinese New Year. The old Mayo plant still required lots of manual
works but at the new plant, its much larger, almost fully automatic
and definitely it can produce bigger productions. Cumanya disebabkan
semuanya serba baru..machine semua still berkilat siap leh wat
cermin..haha..so masih banyak error lagi..dan product yang terhasil
pun tak memenuhi spec sangat..so they still try and error..still
experimenting to know which conditions are optimum for their
productions.
I also learnt the flow processes of those products from (warehouse 1
and cold rooms) where there kept their raw ingredients until they
palletized those products and kept them in warehouse 2 as they are
ready to be lift up and move into uncountable container lorry for
transporting purposes.
Those workers are so nice and welcoming…they share anything that I
asked without hesitation..Although they have no degree or diploma
certificates..but their 10-13 years of experiences worth even more!
You can ask anything…and in just a blink of eyes they can answer it!
Kadang-kadang tu mereka terang terlebih laju..haha “ pak cik stop
dulu..bagi saya tarik nafas jap..ok leh ulang balik tak?” Hahah XD
On 1978..this factory was located at Meru, Klang. Then on 2004, KFC
Holding bought 70% share holders of RFI and then they moved to the new
factory at North Port Klang. Banyak pekerja lama turut ikut berpindah
ke kilang baru dan bekerja sehingga kini..dan ramai dari mereka yang
telah dinaikkan pangkat ke line leader disebabkan pengalaman mereka
yang luas…
Cumanya mereka terangkan secara process flow je.. taklah scientific
sangat..for instance, I asked one of the worker at warehouse “adakah
bahan allergen diasingkan” dan dia jawab “yup allergen perlu
diasingkan sebab serangga suka hurung”. Although we know the reasons
we need to separate allergen and non allergen is to avoid cross
contamination..but might be his answer was based on his experiences..
Who knows kan? Huhu..so after asking them..i need to go back to the
office..open up the work manual instructions or SOP..and read it as it
can help me understand better.
Besides that, I also learned about HACCP, Sanitation programs and CCP
for each station. There are different uniforms for different stations
and different color code for each station. They gave me a lab coat,
boot, and disposable hair net. I also learnt about management. I
learned a little bit how a lines supervisor works..its actually pretty
hard..you need to know how to deals especially with foreign workers..
Did I tell you guyz there are lot of workers who are originally from
Bangladesh and Nepal?? *Orang Nepal rupanya macam orang melayu!! Saya
selalu salah sangka yang dorang ni orang melayu..haha. At the same
time, I need to learn their “language” as they are not that good in
BM..
The tips that I got from the supervisors is to restructure my
sentences when I need to talk with them..its more to ayat tunggang
terbalik ..Pernah sekali saya tanya “baiya bila sos nak start
jalan?”..and he is so blurred!! Then I restructured my sentences “
Baiya..itu sos cili..bila mau jalan?” sambil menunjukkan kearah jam
dinding..barulah dia faham..At first its quiet weird for me to
restructure my sentences but I think I already “master” this new
language :P
The production line will be hectic like crazy during downtime, because
it can affect the productions plan that already being planned for a
week. By this problem, many productions lines are disturbed. Some of
them need to be hold, or being put aside as “work in progress” (WIP),
rework or even worst the products need to be rejected. For example, if
the problem comes from filling station, the products can’t be filled
yet but at the same time the product has already being cooked
completely.
As the technicians struggling to fix that machine, the product’s
temperature may drop. Thus, it not fulfills the requirement of CCP
while filling process takes place (min 80c). Waktu ini la QC sangat
diperlukan. QC needs to check and decide either to hold the products
or rework them (masak balik) or other options that suitable in that
condition. Sebab kalo temperature kat CCP rendah..kita tak dapat sos
yang mempunyai viscosity standard..ia akan lebih cair.. *Rework pun
bukan rework semuanya sekali gus..They will use only about 20% of the
rework products and then will be mixed up with the new
productions..sebab kalo rework semua sekali gus dikhuatiri akan
menjejaskan qualiti. Sebab tu kene guna 20% je..then next
production..gune lagi 20%...
I think i write too much already..Don’t know if anyone willing to read
such long post like this..haha Actually I want to tell you guyz about
the process involve in this factory..but I need to reconfirm back
with my supervisor either I am permitted to do so.. I'm afraid I'll be
sharing things that I should not share..*I already signed the PNC
Hurm..to all my juniors especially to gentleman..kalau nak practical
tu carilah geng yek..sebab mostly foodtech ni ramai perempuan..Di sini
ada 5 orang student practical yang dari kos food tapi 4 orang tu
perempuan!! Saya seorang je lelaki..kalo ada geng rumah sewa pun leh
bayar kurang..segalanya urusan akan lebih mudah la..huhu
For my third week I already being assigned for two mini projects..im
quiet busy with those projects for a while..Hopefully I can share more
stories on my next post ..
Miss u guyz!! *Ok saya tipu..hahah
Hye everyone..salam semua
Seems that many of my friends already shared their valuable thoughts
and experiences.. So may I join you guyz here?? ngeh3 Since I never
post any of my experiences yet for the past 2 weeks of my
practical..so here we go..I’ll summarize up what have I did and what
have I learnt so far..
Ok..i request to have my practical under KFC Holdings and was hoping
they will send me to Ayamas Corp..but unfortunately they posted me to
Region Industries Sdn Bhd (RFI). But no regret..i still enjoy most of
my time doing my practical here! Ironically Ayamas Corp is just
adjacent to RFI T_T it so near..kalo jalan kaki pun peluh tak sempat
nak keluar sebab dekat sangat haha
Hurm...how am I going to start..its so much to tell!! Fine..Let start
with this…to Prof Abdullah your ex-student Mr. Murat Hanafiah kirim
salam..im quiet surprise he is your ex student..anak didik prof
nampaknya ada di seluruh Malaysia haha..fyi he is our senior
production manager..a very important person in RFI..and Mr Murat is my
supervisor for this time being since our production executive had
resigned last November.
Owh ya..according to the formal letter given by KFC Holding..it is
clearly stated that they will attach me at production department..so
sadly I’m not much exposed in QC or R&D department..but I try to sneak
in to those departments and try to learn something! ngeh3 so far I’ve
asked QC seniors or even QC supervisors to know a little bit regarding
things that being conducted by QC department..*for example I watched
and learnt about CIP in mayonnaise station, asking what roles of QCA
at Bottling station and Hassia Station and many more. *Did you guyz
noticed that QCA doesn’t required any related food certification??
Just based on SPM, you can apply for the post of QCA...i thought this
post require at least diploma certificates in Food studies..but I
guess I was wrong…
So since my territory is only Production department…then I was
assigned to fully master this department in a period of a week..This
factory is quiet huge and even within two weeks…I still have many
questions in my head..To make this task even more interesting..i need
to explore this department by myself..ok..that quiet tough! Ahaha.
Based on what have I read on others comments on Facebook, many of my
friends need to do all the industrial works..in contrast, saya pula
tak berpeluang nak rasa pengalaman macam tu because major productions
flow are conducted by automatic machines..kalau ada yang perlukan man
power pun..pekerja asing dah cukup banyak dah..so I just observe and
observe..*pernah sekali saya cuba nak tolong buat kerja..tapi rasa
kelakar plak sebab macam berebut kerja dengan mat bangla tu..ahhah may
be sebab dia takut kene marah dengan line leader kalau tak buat kerja
kot..heheh
My first week is mainly knowing who is in charge for every machines
and stations..There are several line leaders here..i need to know them
first..so that they can teach me anything that I need to
know..Here..public relations, confidence and being friendly are very
crucial..I learnt to be more proactive..dan pada masa yang sama saya
perlu ringan mulut untuk bertanya..kalau tak bertanya..then I learn
nothing..so kena buang rasa malu tu jauh-jauh..then lebarkan senyuman
anda!! Tanya khabar pekerja-pekerja tu..barulah bila dia nak share
ilmu pun tak rasa keberatan sangat ngee~
Owh I almost forget to tell you guyz..RFI basically known for
products with the name of LIFE..from what I’ve learned..50% of the
products will be used by KFC and Pizza Huts Restaurants..30% for
exports and remaining will be sent to local markets. Usually products
will be export to Singapore, Vietnam (KFC), Bangladesh, Australia, UAE
and many others.
There are numerous products being produced here. Their major products
are chili and tomato sauces (sachet/bottles/ pouches), mayonnaise such
as 1000 island, mayo spread, salad mayo etc.. ( use in KFC’s burgers
and coleslaw, Pizza Hut’s Salad dressing) , spoonable jars such as tom
yam paste, chicken curry, fried chili. RFI also produce soups powder
such as chicken and mushroom soup (for Pizza Hut restaurants) ..and im
telling you guyz the list is unstoppable!! Haha too much to tell ..
This factory operate 24 hours non-stop..
If you guyz noticed at any KFC Restaurants in big cities especially in
Klang Valley, those restaurants are no longer using bottle sauces
anymore..Nowadays, they used sauce dispenser same like what McDonalds
Restaurants had used. Here, the machine used to produce (sauce
dispenser) is called as on-pack machine and the sauces are packed in
pouch with weighed of 3kg. It’s pretty new actually. According to Mr
Murat, this sauce dispenser (3kg pouch) will be the main product as
many KFC restaurants will use it soon. *agaknya KFC rugi kot sebab
ramai yang curi bawak balik rumah botol sos tu! haha sebab tu KFC
gantikan dengan sauce dispenser.
RFI has a new Mayo Plant and insyallah.. will be fully operate after
Chinese New Year. The old Mayo plant still required lots of manual
works but at the new plant, its much larger, almost fully automatic
and definitely it can produce bigger productions. Cumanya disebabkan
semuanya serba baru..machine semua still berkilat siap leh wat
cermin..haha..so masih banyak error lagi..dan product yang terhasil
pun tak memenuhi spec sangat..so they still try and error..still
experimenting to know which conditions are optimum for their
productions.
I also learnt the flow processes of those products from (warehouse 1
and cold rooms) where there kept their raw ingredients until they
palletized those products and kept them in warehouse 2 as they are
ready to be lift up and move into uncountable container lorry for
transporting purposes.
Those workers are so nice and welcoming…they share anything that I
asked without hesitation..Although they have no degree or diploma
certificates..but their 10-13 years of experiences worth even more!
You can ask anything…and in just a blink of eyes they can answer it!
Kadang-kadang tu mereka terang terlebih laju..haha “ pak cik stop
dulu..bagi saya tarik nafas jap..ok leh ulang balik tak?” Hahah XD
On 1978..this factory was located at Meru, Klang. Then on 2004, KFC
Holding bought 70% share holders of RFI and then they moved to the new
factory at North Port Klang. Banyak pekerja lama turut ikut berpindah
ke kilang baru dan bekerja sehingga kini..dan ramai dari mereka yang
telah dinaikkan pangkat ke line leader disebabkan pengalaman mereka
yang luas…
Cumanya mereka terangkan secara process flow je.. taklah scientific
sangat..for instance, I asked one of the worker at warehouse “adakah
bahan allergen diasingkan” dan dia jawab “yup allergen perlu
diasingkan sebab serangga suka hurung”. Although we know the reasons
we need to separate allergen and non allergen is to avoid cross
contamination..but might be his answer was based on his experiences..
Who knows kan? Huhu..so after asking them..i need to go back to the
office..open up the work manual instructions or SOP..and read it as it
can help me understand better.
Besides that, I also learned about HACCP, Sanitation programs and CCP
for each station. There are different uniforms for different stations
and different color code for each station. They gave me a lab coat,
boot, and disposable hair net. I also learnt about management. I
learned a little bit how a lines supervisor works..its actually pretty
hard..you need to know how to deals especially with foreign workers..
Did I tell you guyz there are lot of workers who are originally from
Bangladesh and Nepal?? *Orang Nepal rupanya macam orang melayu!! Saya
selalu salah sangka yang dorang ni orang melayu..haha. At the same
time, I need to learn their “language” as they are not that good in
BM..
The tips that I got from the supervisors is to restructure my
sentences when I need to talk with them..its more to ayat tunggang
terbalik ..Pernah sekali saya tanya “baiya bila sos nak start
jalan?”..and he is so blurred!! Then I restructured my sentences “
Baiya..itu sos cili..bila mau jalan?” sambil menunjukkan kearah jam
dinding..barulah dia faham..At first its quiet weird for me to
restructure my sentences but I think I already “master” this new
language :P
The production line will be hectic like crazy during downtime, because
it can affect the productions plan that already being planned for a
week. By this problem, many productions lines are disturbed. Some of
them need to be hold, or being put aside as “work in progress” (WIP),
rework or even worst the products need to be rejected. For example, if
the problem comes from filling station, the products can’t be filled
yet but at the same time the product has already being cooked
completely.
As the technicians struggling to fix that machine, the product’s
temperature may drop. Thus, it not fulfills the requirement of CCP
while filling process takes place (min 80c). Waktu ini la QC sangat
diperlukan. QC needs to check and decide either to hold the products
or rework them (masak balik) or other options that suitable in that
condition. Sebab kalo temperature kat CCP rendah..kita tak dapat sos
yang mempunyai viscosity standard..ia akan lebih cair.. *Rework pun
bukan rework semuanya sekali gus..They will use only about 20% of the
rework products and then will be mixed up with the new
productions..sebab kalo rework semua sekali gus dikhuatiri akan
menjejaskan qualiti. Sebab tu kene guna 20% je..then next
production..gune lagi 20%...
I think i write too much already..Don’t know if anyone willing to read
such long post like this..haha Actually I want to tell you guyz about
the process involve in this factory..but I need to reconfirm back
with my supervisor either I am permitted to do so.. I'm afraid I'll be
sharing things that I should not share..*I already signed the PNC
Hurm..to all my juniors especially to gentleman..kalau nak practical
tu carilah geng yek..sebab mostly foodtech ni ramai perempuan..Di sini
ada 5 orang student practical yang dari kos food tapi 4 orang tu
perempuan!! Saya seorang je lelaki..kalo ada geng rumah sewa pun leh
bayar kurang..segalanya urusan akan lebih mudah la..huhu
For my third week I already being assigned for two mini projects..im
quiet busy with those projects for a while..Hopefully I can share more
stories on my next post ..
Miss u guyz!! *Ok saya tipu..hahah
Rikevita by nurul hidayah mohd noor
on this week, there are 7 batches of cake emulsifier are being
produced by our factory.
for every batch, i have to check the sample for the first and last
parts of the batch...
so, if there are 7 batches of cake emulsifier, i have to produced 14
cakes for the analysis...
as the cake emulsifier are the EP product, I have to involve in the
analysis for the product...
for cake emulsifier, i have to prepare an analysis to check the SG
(specific gravity) for the emulsion.
as experienced in the bakery lab, i have to prepare the cake using the
cake emulsifier produced...
its a little bit tiring as in the bakery lab, there is no chair and
the time for the analysis is quite long....
the cake produced is the basic sponge cake without any flavour...
usually, the SG of the emulsion are within the range that the customer
wants...
during my analysis, there is one problem occur which is the SG is not
in the range...
although it have been repeated two times, the SG is still high...
so, the product has been rejected...
to overcome this problem,the product are being sent for re-sampling...
or, other ways is to re-label the products...
some of the emulsifier produced are from the same type but may have
different brand...
so, the product that have problems with its SG, will be sent to change
the label for the product with other brand that do not require low
SG...
i'm so sorry as there are not so many information that i can share
with all of u...
but, i will try my best to share as many as i could...
sharing is caring!!
produced by our factory.
for every batch, i have to check the sample for the first and last
parts of the batch...
so, if there are 7 batches of cake emulsifier, i have to produced 14
cakes for the analysis...
as the cake emulsifier are the EP product, I have to involve in the
analysis for the product...
for cake emulsifier, i have to prepare an analysis to check the SG
(specific gravity) for the emulsion.
as experienced in the bakery lab, i have to prepare the cake using the
cake emulsifier produced...
its a little bit tiring as in the bakery lab, there is no chair and
the time for the analysis is quite long....
the cake produced is the basic sponge cake without any flavour...
usually, the SG of the emulsion are within the range that the customer
wants...
during my analysis, there is one problem occur which is the SG is not
in the range...
although it have been repeated two times, the SG is still high...
so, the product has been rejected...
to overcome this problem,the product are being sent for re-sampling...
or, other ways is to re-label the products...
some of the emulsifier produced are from the same type but may have
different brand...
so, the product that have problems with its SG, will be sent to change
the label for the product with other brand that do not require low
SG...
i'm so sorry as there are not so many information that i can share
with all of u...
but, i will try my best to share as many as i could...
sharing is caring!!
Rikevita by shela ariff
Dayah MN has been told what we already do in Rikevita for this 3 weeks....
If Dayah MN more focused to do analysis for EP (emulsifier preparation)
products,
I was heavily involved for the EMA (emulsifier monoglycerate acetylated)
analysis products.
The samples for EMA products are usually in the powder, liquid or in the
semi liquid form.
I usually tasked to carry out analysis for the product in powder form.
Only 2 days before I was running a new analysis for the samples in the
liquid form.
Just like Dayah MN said, all the analysis just like chemistry experiments.
I have to deal with all sorts of dangerous chemicals.
So safety is a priority, I always wear gloves and mask when carrying out
analysis.
At the moment, Me and Dayah MN run a different analysis....
Dayah MN need to run for microbe test, fat analysis
(soxhlet),LOD (loss on drying), RI, and viscosity for EP products.
While, I need to run a test of IV (iodine value), AV(acid value), SV
(saponification value), OHV (hydroxyl value), and GPC (gas permeation
chromatography) for EMA product.
Let me share the function of all analysis that I have been done...
analysis only done if have a request from customer.
Particle size analysis is a simple test. Just like a sieving test that we
had learned in class Pn. Norlia.
The function of this test to ensure that particle size is always in the
specific range to avoid the product become lumping when processed.
Ok....
I think enough for now. Me and Dayah MN will try our best to share our
experience in Rikevita.
just like Dayah said "sharing is caring!!"........
If Dayah MN more focused to do analysis for EP (emulsifier preparation)
products,
I was heavily involved for the EMA (emulsifier monoglycerate acetylated)
analysis products.
The samples for EMA products are usually in the powder, liquid or in the
semi liquid form.
I usually tasked to carry out analysis for the product in powder form.
Only 2 days before I was running a new analysis for the samples in the
liquid form.
Just like Dayah MN said, all the analysis just like chemistry experiments.
I have to deal with all sorts of dangerous chemicals.
So safety is a priority, I always wear gloves and mask when carrying out
analysis.
At the moment, Me and Dayah MN run a different analysis....
Dayah MN need to run for microbe test, fat analysis
(soxhlet),LOD (loss on drying), RI, and viscosity for EP products.
While, I need to run a test of IV (iodine value), AV(acid value), SV
(saponification value), OHV (hydroxyl value), and GPC (gas permeation
chromatography) for EMA product.
Let me share the function of all analysis that I have been done...
- AV = to test the num. of mg of KOH required to neutralised free fatty acid in 1 g sample.
- IV = to test the num. of g of iodine absorbed by 100 g of fat under test condition. it measures unsaturation of fat and oils.
- SV = to test the num. of mg of KOH required to neutralised free fatty acid and saponify the esters in 1 g of sample.
- GPC = determine and quantitating the specific types of esters present in the product by separation using mobile phase and stationary phase. Usually, the types of peaks are show the present of TG (triglyceride), DE (diester), MG (monoglyceride), DG (diglyceride), FG (freeglyceride) in the sample.
analysis only done if have a request from customer.
Particle size analysis is a simple test. Just like a sieving test that we
had learned in class Pn. Norlia.
The function of this test to ensure that particle size is always in the
specific range to avoid the product become lumping when processed.
Ok....
I think enough for now. Me and Dayah MN will try our best to share our
experience in Rikevita.
just like Dayah said "sharing is caring!!"........
Rikevita by nurul hidayah mohd noor
unlike other factory,rikevita does not produce finished food
product...
rikevita is producing the emulsifier for the cake,ice cream and other
products, one of the customer is apollo. 95% of the product produced are being exported to the other
countries..
we have to analysed the product before being released to the
customer...
some of the product are the same product but may have different brand
for different customer...
early in the morning, we have to follow the other staff to take sample
from the production area.
then,there is a meeting between the QC staff with the head of
department to divide the sample for each person to be tested...
usually, i have to run test for EP(emulsifier preparation) sample...
so, the test involve for the EP sample are microbe test, fat analysis
(soxhlet),LOD (loss on drying), RI, and viscosity...
for microbe test, the sample are being test for the presence of
coliform, yeast and mould and total plate count...
LOD is for moisture content test and RI is same as ashing...
on behalf of shela,usually, she has to run sample from EMA (emulsifier
monoglycerate acetylated)
so, the test involve are IV (iodine value), AV(acid value), SV
(saponification value) and OHV (hydroxyl value)....
All of these are as the same as chemistry experiements....
From HPA by Nadhirah Nordin
Hey guys! It will be going the forth week of industrial training,
which means 11 more weeks to go. Running the same test during the past
weeks, and lucky enough when the QA takes me to the other branch
somewhere in Napoh, Kedah. They make cordial, RTD and also cookies
there. As the oven in FTM lab can be said big enough for me, the oven
they have here is as big as a store room. Haha. The machine they used
for RTD and cordial is almost same with the one used by World
Prominence. They have the extraction tanks to extract fruit juice,
cooking tanks, storing tanks, filling machine and also shrink
machine.
Back to Arau (place where I have been sent for LI), I have gone to the
pharmaceutical production line too. This factory has got GMP
certification, so I have to wear the astronaut suit. The personel QC
has explain to me the whole process from receiving the raw ingredient
until the packaging.
The busiest production line is the one which
produces pharmaceutical product and also Radix coffee as they also
have to covers Indonesian market. Rupanya for pharmaceutical product
processing, one of the step involve is polish process. No wonder la
capsule that we usually consume is always berkilat-kilat. Heheh. Plus,
there must be a machine called dust collector in each of the
processing room. The dust collector will act as a vacuum to suck all
the dust in the air to reduce it to acceptable condition.
There're also 2 different building produces 2 other products which is
coffee (Radix, Radix cocoa) and also sauces (chilli, Roselle). I
haven’t gone there yet, but that is not a big problem actually. I just
have to follow the personel QC when they have to check the product
later. Being too excited to learn too many things in one time might
not works right? So just make it steadily and constantly. (alasan..
hehe!) By the way, HPA also have their slaughtering house in Kodiang,
so hopefully I got the chance to go there one day.
I have told the QA that I would like to help them (anything that would
gives benefit tho the company). he suggested to help them in preparing
the GMP documentation/report for their new factory in Napoh which will
produces HPA cosmetic products. So I would be able to apply what I
have learned in Mr. John’s lecture on GMP and also my experience
during preparing our report for factory auditing.
But I just feel that
it is too hard for me to do it all alone to prepare the new factory
layout and also the requirement that they should have in getting the
GMP certification. Is it still can be considered covers what we learn
in our course Prof? It would sounds better if they ask me to help them
on their new food factory. Hehe.
So currently I have been helping the QA in preparing new version of
HPA R&D work description to replace the older version in order to make
their documentation up-to-date. And on the same time, I am still doing
all the lab tests (moisture analysis and also ujian pengecaian
kapsul). Remember the new product that we have been working on and
where the sample has been sent to somewhere else for further analysis
that I have told in the last post? We have received the analysis
result.
Alhamdulillah, everything is going fine and the product will
be launch next month :) Insyaallah.
Reply from nurul afiqah at Ajinomoto,
hey hey nad! assalamualaikum :D just to share, here at aji also have dust
collectors too. so how do they make sure these dust collectors work? they'll
have a test called 'particle count test'. so if the particle count results
is higher, there's something wrong somewhere. the dust collector is actually
extremely important especially when handling products with powdered spices
ingredients because without it factory operators may be facing serious
respiratory problems (rs amek medic plk instead of food tech dgn statement
tersebut. hehe.)
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