Internship report on kishlay snacks pvt. ltd. guwahati

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SUMMER INTERNSHIP REPORT
Submitted By
Dipjyoti Deka
University Roll No. - DC2015BTE0167
Department of Mechanical Engineering
Assam Don Bosco University
SUBMITTED TO:
Kishlay Foods Pvt. Ltd
And
Department of Mechanical Engineering
Assam Don Bosco University
DURATION OF SUMMER INTERNSHIP:
8th
June to 3rd July 2018

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DECLARATION
I hereby declare this Summer Internship Report is an authentic record of my own
work as requirements of Summer Internship during the period from 8th June to 7th July
for the award of the degree of B.Tech. (Mechanical Engineering), Assam Don Bosco
University, Airport Road, Azara, under the guidance of Abu Guhi.
Signature
Dipjyoti Deka
University Roll No. - DC2015BTE0167
Date:

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ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the Kishlay Factory for their sincere guidance
I received to uphold my practical skills in an Industry.
First of all, thanks to the maintenance head Mr. Pankaj for giving encouragement,
enthusiasm and invaluable assistance to me. Without all this, I might not be able to complete this
project properly.
Second, I would like to thank my project guide Abu Guhi for giving me such a nice,
knowledgeable guidance and support during my project training.
Thirdly, I also want to express my deepest thanks to Engineers of maintenance department.
They helped me a lot in dealing with this internship and understanding different machines.
Besides, I would like to thank the workers and their friendship towards me and making a
pleasure-training environment in the industry.
Thanks also to all the machine operators who showed me a right way to observe the
machines also they helped to understand the mechanisms of different machines.
A paper is not enough for me too express the support and guidance I received from them
almost for all the work I did there.
Finally I apologize all other unnamed who helped me in various ways to have a good training.

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ABSTRACT
Industrial training is an important phase of a student life. A well planned, properly executed and
evaluated industrial training helps a lot in developing a professional attitude. It develop an
awareness of industrial approach to problem solving, based on a broad understanding of process
and mode of operation of organization. The aim and motivation of this industrial training is to
receive discipline, skills, teamwork and technical knowledge through a proper training
environment, which will help me, as a student in the field of Mechanical Engineering. During a
period of 1 months training at Kishlay Snacks Pvt. Ltd., I was assigned to study different machines,
operation and maintenance in order to evaluate the efficiency of production to help the company
to reduce maintenance issue. As a result I vital to achieve the minimum requirement of the
company, it will help the company to reduce the maintenance issue. Throughout this industrial
training, I have been learned new organizational behavior that is required for my future.

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Table of Contents
Sl. No Page Title Page No.
1. About Kishlay 7
2. Chapter 1.
Introduction 8
3. Chapter 2.
Manufacturing units 9
4. Chapter 3 10-23
MACHINE STUDY
Potato Chips production unit
Extruded snacks production unit
Kurkure Snacks Extruder
Corn Puff Extruder
Flexible Screw Conveyors
Areas of Application:
Features
Continuous Dryer
Features
Packaging machine
Features
Astro 103
Continuous Fryer Machine / Roaster
Swing-arm-type fryer
Continuous automatic fryer
Puff extruder
Seasoning Drum
Snack flavor application systems
Bucket Elevator
Bucket elevator type
Fabcon)
Operations
Sun Agro Machines
Varlift
5. Chapter 4 20-23
Extruded snacks production: Kurkure
Description of Manufacturing Process
The Process Flow
Construction
Potato Snacks Production
Quality Control
Byproducts/Waste
6. Chapter 5 24-27
Skills and Techniques learned during Internship
Role of Internee during Internship
Conclusion
Reference

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CHAPTER 1
INTRODUCTION:
After 1995, India has seen a massive change in Snack food market. There is a rise in demand of
snacks market which drives manufactures to grow and operate in this segment lucratively.
Due to the busier lifestyle in the recent past, the demand for convenience products has
increased a lot with the thrust of packaged food in India. With the advancement of technology,
urbanization, increase in purchasing power, growth in female work population, expansion of
nuclear families has augmented the business of the packaged snack food and attracted a large mass
toward the snack market in India. In order to save time, people are gradually shifting to ready to
eat food items. The growth rate of the packaged food market has been remarkable in last five years.
The food industry has expanded at the rate of 15.6% over the last few years. The consistent growth
rate presently outlooks for driving growth in future too.
The consumers are looking forward for healthier and flavorful options in the food market.
There is an increase in the consumer interest towards snacks as there are various brands in this
segment with newer technology and more benefits giving them refreshing and quick meals.
The fast expanding retail network and the convenience and ease of acquiring it, contributes
towards the rapid growth of the industry. I addition, there are no such regulations and Government
policies regarding the establishment of such companies in India which motivates the manufacturers
to set up its units.
Apart from this, there are some challenges the Indian snack industry has which can result
in a setback. Despite of so many companied in the market, the market yet needs to find Indian
flavors to fully satisfy them. Chips, Extruded Snacks and biscuits are still considered by Indians
and so new categories are created which would require time and persistence. Healthier and tastier
snack is still needed to raise the demands.
The Indian snack industry snack industry has major trends and developments in India over the
years. It is stable at present and has strong growth potential in future.
India snacks market is segmented into Extruded Snacks, Chips, Namkeen and Others. In
terms of market value share, Namkeen has the highest market share compared to all other segments
Extruded Snacks, Chips and Others. At present, in both organized and unorganized market,
Namkeen is the leading segment.

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So the companies are taking relevant steps to retain, sustain and grow in the market. They
are trying their level best with various innovative options, tastes and flavors in the industry meeting
the expectations of Indian consumers.
In the north eastern region of India Kislay has fulfilled the different snacks needs of
customers in various verities with a great nutrition and tastes. Over 17+ years Kishlay’s Guwahati
house introduces more than 15+ verities of snacks and biscuits which include the following
categories-
Kishlay
Balls Crisp Puffs Crispy Snacks Potato Ring Tri Cone
Cheese Masala Bully
Cheese
Mast
Pudina
Spicy
Treat
Jaadu Golden
Puff
Lime
n
lemon
Super
ooh
Jumping
Jacak
Fun
Launcher
Tomato
Rice
Crazy
Balls
Chilly
Tomato
Mix
Achaar
Boom
Boom
Noodies Modly
Twists
Choco
Pillows
Pizza Popcorn Caramel
Popcorn
Pasta SnakesDilrubaChatpata
Masala
Pik Nic
Spicy
Treat
Cream
Onion
Mast
Masala
Standard
Salted
Tomato
Punch
Extra
Slices
Munchy
Masala
Chee
sy
Potato
Feast
Tasty
Tomat
Plain
Salted
Cream
N Onion

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Chapter 2
2.1 Manufacturing units
Inside Kishlay’s Guwahati house there are basically 4 manufacturing units which are-
1. Potato Chips production unit
2. Extruded snacks like-Rings, kurkure, Pasta production unit
3. Extruded snacks like-Balls, Tricone, Puffs production unit
4. Biscuits production unit

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CHAPTER 3
Machine Study, Description of different snacks
3.1 MACHINE STUDY
3.1.1. Potato Chips production unit: The processing line of potato chip is of SIDDHIVINAYAK
AGRI PROCESSING PVT LTD Company.
Following are some features of the “SV” Potato Chips Processing line -
a) All process equipment fabricated in industry-grade stainless steel.
b) Auxiliary support components sourced from trusted international brands.
c) Wide range to cater to requirements of the clients. Capacity ranging from 200-1500 kg/hr.
d) Human-Machine Interface (HMI) for the line control comprising of a PLC Panel of
international standards which ensures complete automation of the line.
e) Electrical interlocks for smooth and safe operation and to control and interlink the line
equipment.
3.1.2 Extruded snacks production unit: The processing line of extruded snacks is of
Fabcon Machines Pvt. Ltd Company
Following are some features of the processing line-
a) Direct expanded snacks
b) Continues cooking food extruder
c) Specially design with main bearing nousing fitted with bearing
d) The main structure is made by mild steel tube frame with feeding screw
e) Screw and barrels and made of alloy steel die head bolts and nuts are of high tension
f) All standard fitting
Technical specifications
3.1.2.1 Kurkure Snacks Extruder
3.1.2.2. Corn Puff Extruder

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3.1.3 Flexible Screw Conveyors
The flexible screw conveyer is a Tube type conveyer which is used to convey granule products by
using a screw which moves inside a consolidated tube pushing the material forward.
A smart customer always wants a product, which full fills the need of the hour with quality and
precision, which brings the Flexible screw Conveyors in the picture.
A Flexible screw conveyer also known as an FSC is an engineering marvel which takes care of all
the problems of conveying Dry, bulk solids or any other powder ingredients.
It is a complete powder handling system.
Areas of Application:
Spices.
Flour, Grits, Meals etc.
Whole pulses.
Sugar
Salt
Premix-Food & Beverages etc.
Features:
i. Design Simplicity:
The electric motor driven spiral, which is the only moving part, rotates within a sealed tube,
moving the material along the tube. The design simplicity eliminates the need for any additional
operating equipment such as filters or bearings- all adding up to a system that’s low on installation
and maintenance costs and high on efficiency and performance.
ii. Constant Remixing:
The unique action of the flexible spiral conveyer eliminates the risk of the product separation that
can take place in the conventional pneumatic conveying systems where mixed materials have
components with different densities and/or particle size, in fact the conveying action ensures
constant remixing; essential when feeding pre-mixed ingredients to packaging and tableting
machines.
iii. Low Maintenance:
Only moving part of our flexible screw conveyor is its robust inner spiral, trouble-free operation
is ensured.
iv. Control:
Control equipment ranges from simple starters, level controls and timers to PLC systems enabling
multi-ingredient recipe variations to be weighed, blended and conveyed.
v. Spiral for every occasion:
vi. Round: For Most Applications.
vii. Flat: For fine powders.
viii. Pros crew: For difficult materials.
ix. Dust Free:
Totally sealed during operation and because air is not used as the conveying medium, there is no
risk of dust contamination escaping in to the atmosphere- critical for applications involving active
pharmaceuticals and hazardous chemicals.
x. Food Grade Certified:

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The FSC tube is made up of Ultra High molecular weight treated PE or UHMWPE which is a food
grade material along with the inner screw made up of stainless steel which makes it completely
safe for food product propagation.
xi. Easy to Clean:
Optional, interlocked, quick release connectors facilitate rapid dismantling and reassembly where
dry cleaning of the spiral, tube and connectors are essential. Conveyors can be emptied of residual
material by reversing the motor and then flushed through with water or cleaning solutions.
xii. Gentle Handling:
Little to no product degradation.
xiii. Easy installation, minimum distribution:
Linked conveyors with multiple intake and discharge units can also be fitted enabling materials to
be conveyed over greater distance, multiple discharge points can be placed along a horizontal
distance which, when combined with elevating conveyors, can lift ingredients from storage bins
and convey at ceiling heights to feed a line of processing or packing machines.
3.1.4. Continuous Dryer
Technical specifications
Features
i. Specially designed for frying the Snacks, Pallets and Feed
ii. Roasting oven used for drying all kinds of stick, piece, grain etc.
iii. Different types of dryer according to layer, length or energy are available
iv. The whole machine is compact design, logical and easy operation.
v. Driving system adopts double pitch roller chain driving, circulating drying, and
vi. Balanced running, never jam.
vii. Drying temperature and time can be adjusted, effect of drying is capitally
viii. With high efficiency fuel saving system, reasonable heat distribution, material be
ix. heated equally, low energy but large output High production Capacity
x. Continuous line type of Chain Dryer
3.1.5. Packaging machine: There are in total 22 packaging machine, 6 in potato processing unit
and 16 in extruded snacks processing unit. They are of Pace Packaging Pvt. Ltd, Astro Company.
Following are the details of the packaging machine-
3.1.5.1. Pace P250 1S is an entry level vertical form fill seal machine with servo driven horizontal
sealing & drive based bag pulling. P250 1S is ideal medium speed bagger, which can be
synchronized with any one of the following fillers to pack any kind of solid products:
Multihead Combination Weigher
Volumetric Filler
Auger Filler
Linear Weigh Filler

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Index Conveyor Belt
Features
Controlled by most advanced PLC and Motion Controller with Touch Screen operating
panel.
Inbuilt self-diagnostics features.
Powered reel unwinder with air shaft for easy loading of the film roll.
Integrated servo driven unwinder mechanism for servo driven machine.
The newly designed bag forming parts for easy and fast changeover.
The speed of the machine and the bag length can be adjusted even while the machine is in
operation.
No product No bag feature ensures no waste of bags. Alert indication for end of film roll.
Password protection for settings.
Production data in various formats.
3.1.5.2. Astro 103
Ishida's Astro bagmaker is an ideal solution for snack food manufacturers requiring pillow packs
and alternative formats such as gusset and block-bottom packs. Supplied as a stand-alone unit to
interface with existing weighing equipment, or as part of a complete line, the Astro bagmaker
offers a compact design that is an easy fit upgrade for existing lines. Further benefits include:
• Compact, robust design
• Multiple pre-set programs for quick product changeover
• Accurate film positioning through patented pull-down belt system
• Available in left-hand, right-hand and twin tube configurations
• Decreased product waste, giveaway, downtime for cleaning and maintenance
• Optimised presentation and seal quality

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• Economy of film use
• Operator-friendly touch screen control
3.2.6. Continuous Fryer Machine / Roaster: Apart from the chips frying machine kishlay has 4
frying machine one of which is of Fabcon Company two are of Jinan Saixin Machinery co. ltd.
and one of Syam Engineers foods production.
Apart from the brand name their features and working procedures are almost same. The
following are the details of the machineries of
Jinan Saixin Machinery Co. Ltd
3.2.6.1 Characteristics of the swing-arm-type fryer:
1. The integration of oil frying, oil filtering, oil throwing, cooling and conveying makes
structure compact, function perfect and occupying floor less.
2. The entire frying procedure is controlled in concentration with automatic operation of a
high degree
3. Frying temperature and time, oil filtering time and oil throwing time can been adjusted so
as to meet the requirement of various products.
4. A high-efficient oil /gas burner. An insulating chamber proper. Quick temperature rise.
Less energy consumption.
5. Optional two kinds of control modes, automatic and manual with flexible manipulation.
·

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3.2.6.2 Characteristics of the continuous automatic fryer:
1. Optional heating modes, electric power, oil burning and gas burning. Quick temperature
rise. Less temperature change.
2.A dynamic oil filtering system with removing dregs at any time ,keeping oil fresh and
eliminating oil deterioration due to residual dregs .
3. An optimized boiler proper structure. Less oil quantity. High oil turnover rate.
4. The boiler proper can free separates from the conveying unit to facilities clear -up. Material
charging by vibrating with even material charging.
5. The device may take electricity, oil or gas as energy source.
·
Syam Engineers Food Process
Features
1. Single Stainless net conveyor
2. Frequency VFD converter
3. Self-locking motorized screw jacks raise the hood (for Hood Lifting)
4. Drum Coarse Oil Filtration (Oil Filtration system)
5. Clean-in-place spray nozzles in the hood (Optional)
6. Oil level control is maintained automatically.
7. PLC touch control panel (Optional)
3.2.7 Puff extruder: Company Name- Jinan Saixin Machinery Co. Ltd
Quantity- 3
Single screw puffed extruder adopts corn kernels, rice kernels as raw material, by using high-
shearing to get them puffed rapidly with high efficiency and energy saved. It bears advanced
cooling system and PLC control system, and is easy in operation and enable long lifetime of
machine parts, the screw and barrel/ sleeve can last more than 5000 hours. It can be applied to
produce many different kinds of puffed snacks in good taste.

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3.2.8 Seasoning Drum:
Companies: Flavorite(1), Fabcon(1), Syam Engineers Food Process(2), Jinan Saixin Machinery
Co. Ltd(1)
Quantity: 5
Seasoning is an integral part of any snack product, it is a way to differentiate and create interest in
The product. The Seasoning systems most commonly used in savoury snacks include:
• Conveyor based dusting system
• Drum based single-stage dry flavor application
• Drum based two-stage oil and dry flavor application
• Drum based slurry
Dry only systems are used on products that have natural tack
• Fried potato chips and crisps
• Fried pellet snacks
Oil and dry systems are used on snacks that do not have natural tack
• Tortilla chips
• Corn chips
• Mini rice cakes or other dry puffed products
• Popcorn
• Baked chips and crisps
• Extruded snacks
3.2.8.1 OIL + DRY FLAVOUR
Two-stage systems are employed when the natural or process induced tack is not present on the
product to be flavored. Oil is sprayed onto the product prior to adding the dry flavor. The
temperature of the product is very important to how much oil stays on the surface, similarly the
dry flavor coverage is totally dependent on oil coverage. An all-in-one package, the two-stage
seasoning - in-kitchen system can handle large product volumes. If temperature is critical the
placement is flexible. This system is the best choice for high absorption products.
3.2.8.2 Snack flavor application systems
Applications system - dry dust applicators
There are various types of dry flavor applicators that can be used for applying seasoning to snack
products, these include Scarf plate dispensers and electrostatic systems.
3.2.8.2.1 Scarf plate feeders
Scarf plate feeders are easy to operate, easy to clean and can work with most products, creating a
consistent curtain of seasoning. On the scarf plate feeder the bias is cut on a vibratory or horizontal
motion conveyor, and a screw feeder is used to feed the spice at the desired rate. Electrostatic
applicators work by applying a static charge to the powder, oil or slurry as it is being sprayed onto
the base product. As the flavorings and coatings become ‘negatively’ charged, they repel each
other making a nice curtain or spread of seasoning.
Electrostatic applicators offer a reduction in dry powder usage, even coverage and a cleaner
working environment.

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3.2.9. Bucket Elevator:
A bucket elevator, also called a grain leg, is a mechanism for hauling flow able bulk materials
(most often grain or fertilizer) vertically.
It consists of:
1. Buckets to contain the material;
2. A belt to carry the buckets and transmit the pull;
3. Means to drive the belt;
4. Accessories for loading the buckets or picking up the material, for receiving the discharged
material, for maintaining the belt tension and for enclosing and protecting the elevator.
3.2.9.1. Bucket elevator type
There are three common bucket elevator designs seen in bulk material handling facilities
worldwide:
1) Centrifugal Discharge Elevator - Typically, this is the style of elevator used in grain handling
facilities we are all familiar with along rivers, ports or on the farm.
2) Continuous Discharge Elevator - This style bucket elevator is used typically to discharge
sluggish and non-free flowing product where the elevator buckets discharge on top of each other.
Speeds are run in the 125 fpm range to accomplish this type of centrifugal force.
3) Positive Discharge Elevator - Elevator design where the buckets are used to elevate
commodities such as popcorn, candy and potato chips where the utmost concern is on gentle
handling and finished food grade applications. This style elevator bucket operates off a double
strand chain where they are held in place by two pins so the bucket is allowed to freely swivel. To
discharge the bucket it's mechanically tripped to flip and discharge but until this action the bucket
is held parallel with the floor and upright. These elevators typically form an "S" or "L" in design
and run throughout a plant.
Inside kishlay’s plant there are in total 4 bucket elevator which are of Fabcon(2), Sun Agro
Machines(1), Varlift (1)
Features (Fabcon)
• Food Safe.
• FDA certified.
• Completely Modular Design
• Easy to Operate.
• Easy Cleaning and Maintenance.
• CNC/Laser cut finish for fine detailing.
• Completely build with SS 304
• Glass Bead Blasting Finish.

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The perfect fit
Varilift conveyors fit even the tightest installations. Choose from S, C or horizontal configurations
with buckets that can discharge at any point under the horizontal run. Optional multiple infeed and
discharge points allow to accept and deliver product to more than one location.
Clean conveying
Varilift’s unique infeed system eliminates gaps between buckets to prevent product loss. Non-spill
buckets remain upright after dumping, while an infeed leveler prevents product loss. Quick release
one-piece polypropylene buckets simplify cleaning.
Quiet, reliable operation
Drive chains are silently guided by rails, with no sprockets between bends. Automatic chain
tensioner minimizes wear by maintaining minimal tension.
Clean conveying
Varilift’s unique infeed system eliminates gaps between buckets to prevent product loss. Non-spill
buckets remain upright after dumping, while an infeed leveler prevents product loss. Quick release
one-piece polypropylene buckets simplify cleaning.
Auto-stop buckets
Buckets automatically stop if overloaded or jammed. Anti-roll-back feature prevents buckets from
running backwards if the conveyor is turned off while buckets are loaded.
Modular construction
Composed of interchangeable modules, the Varilift can be added to or reconfigured to suit
expansion or changes in the production line.
Specifications

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Chapter 4
Description of production
4.1.1 Extruded snacks production: Kurkure
Production: 100-200 Kg/Hour
Description of Machinery
• Raw Material Mixer
• Input Conveyor for Extruder
• Grain Puff Machine/Extrusion (main production machine)
• Sieve tumbler (separator)
• Input Conveyor for Fryer
• Automatic Fryer
• Seasoning Section with Flavor Applicator
• Output Conveyor for Seasoning
• Packing Section (Auto Vertical Packing - Pillow Pack)
Description of Manufacturing Process
In the mixer the raw materials are mixed and brought to the desired moisture level. The mix is
then transferred to the extruder hopper; a level indicator ensures that the extruder does not run
empty. In the extruder the raw materials are pressed through a die using high-pressure build-
up by the screw and high temperature created by shear between sleeve and screw.
The pressure drop at the die causes the snack to expand and the face cutters set the desired
snack length and mass. After extrusion the snacks are fried for extra crispness and for shelf-
life. They are then coated with oil, and then with flavor powder. Coating takes place in the
rotating coating drum. Now the snacks are ready to be packed; this is best done immediately.
It is recommended that a buffer silo is installed between packing equipment and processing
line, mainly to overcome the differences in operational speed. Kurkure extrusion is the process
whereby grits (of i.e. corn) is forced through a die into the final snack-shape, and flavorings
are added to produce a tasty snack.
4.1.2 Extruded snacks production: Fry Type Snacks, Corn Puff Extruder
Production: 80 – 100 Kg / Hr (Depends upon die shape)
The Process Flow Of the 3D pellet snacks processing line:
1. The materials firstly are blended sufficiently in the mixing machine.
2. The blended materials are fed into the extruder machine to be prepared at high temperature and
high pressure in a short time.
3. The extrudates will be shaped into two layer or single layer based on the final pellet snacks.
4. The semi-foodstuffs go across the pattern machine and shape machine to attain the final shape.

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5. After the process of the drying, baking, frying, flavoring, packaging the pellet snack will be
prepared for sale
Construction of the pellet snacks processing line:
1. Powder Mixer Machine
2. Vacuum Feeding Unit
3. Food Extruder Machine
4. Cooling Unit
5. Pattern Machine
6. Shaper Machine
7. Cooling Conveyor
8. Drying Machine
9. Flavoring Machine
The simple principle of expansion of the pellet snacks allows the utilization of a wide choice of
starch based raw materials. Cereal flours are the most common ones, followed by root starches like
potato and tapioca and cereal starches. A great advantage of the pellet snacks technology is the
possibility of making formulas with peculiar characteristics like high fiber content, multi grain or
multi colored. Although the pellet production process generally includes a step to cook the
starch matrix, allowing the use of raw flours and native (uncooked) starches which are cheap and
widespread, some common raw materials are already cooked, such as the potato based raw
materials like potato flakes and granules. Sometimes precooked or par-cooked cereal’ raw
materials are also used. Pre-cooked materials generally do not require going through the cooking
step but only the phases related to shaping and drying.
Pellet snacks are produced dried and semi-processed for easy storage and shipment and in
a second phase are expanded, seasoned and packed. The pellet snacks’ peculiar capability of
expanding is due to the presence of gelatinized or partially gelatinized starch in their matrix. The
water entrapped into the matrix, if heated rapidly above boiling point, evaporates thus creating an
internal pressure; the gelatinized matrix itself becomes less viscous and keeps the water steam
inside for a certain time increasing its volume. The volume of the product increases and reaches
again rigidity due to lack of water: the result is a light, crunchy and pleasant snack.
4.1.3 Potato Snacks Production:
The process flow diagram is as follows:

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1. When the potatoes arrive at the plant, they are examined and tasted for quality. A half dozen or
so buckets are randomly filled. Some are punched with holes in their cores so that they can be
tracked through the cooking process. The potatoes are examined for green edges and blemishes.
The pile of defective potatoes is weighed; if the weight exceeds a company's preset allowance, the
entire truckload can be rejected.
2. The potatoes move along a conveyer belt to the various stages of manufacturing. The conveyer
belts are powered by gentle vibrations to keep breakage to a minimum.
3. The potatoes are loaded into a vertical helical screw conveyer which allows stones to fall to the
bottom and pushes the potatoes up to a conveyer belt to the automatic peeling machine. After they
have been peeled, the potatoes are washed with cold water.
4. The potatoes pass through a revolving impeller/presser that cuts them into paper-thin slices,
between 0.066-0.072 in (1.7-1.85 mm) in thickness. Straight blades produce regular chips while
rippled blades produce ridged potato chips.
5. The slices fall into a second cold-water wash that removes the starch (/knowledge/Starch.html)
released when the potatoes are cut. Some manufacturers, who market their chips as natural, do not
wash the starch off the potatoes.
6. If the potatoes need to be chemically treated to enhance their color, it is done at this stage. The
Potato slices are immersed in a solution that has been adjusted for pH, hardness, and mineral
content.
7. The slices pass under air jets that remove excess water as they flow into 40-75 ft. (12.2-23 m)
troughs filled with oil. The oil temperature is kept at 350-375°F (176.6-190.5°C). Paddles gently
push the slices along. As the slices tumble, salt is sprinkled from receptacles positioned above
the trough at the rate of about 1.75 lb. (0.79 kg) of salt to each 100 lb. (45.4 kg) of chips.
8. Potato chips that are to be flavored pass through a drum filled with the desired powdered
seasonings.
9. At the end of the trough, a wire mesh belt pulls out the hot chips. As the chips move along the
mesh conveyer belt, excess oil is drained off and the chips begin to cool. They then move under
an optical sorter that picks out any burnt slices and removes them with puffs of air.
10. The chips are conveyed to a packaging machine with a scale. As the pre-set weight of chips is
measured, a metal detector checks the chips once more for any foreign matter such as metal pieces
that could have come with the potatoes or been picked up in the frying process.
11. The bags flow down from a roll. A central processing unit (CPU) code on the bag tells the
machine how many chips should be released into the bag. As the bag forms, (heat seals the top of
the filled bag and seals the bottom of the next bag simultaneously) gates open and allow the proper
amount of chips to fall into the bag.

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12. The filling process must be accomplished without letting an overabundance of air into the bag,
while also preventing the chips from breaking. Many manufacturers use nitrogen to fill the space
in the bags. The sealed bags are conveyed to a collator and hand-packed into cartons.
13. Then the cartons are distributed through distribution channel.
Quality Control
Taste samples are made from each batch throughout the manufacturing process, usually at a rate
of once per hour. The tasters check the chips for salt, seasoning, moisture, color, and overall flavor.
Color is compared to charts that show acceptable chip colors.
Preventing breakage is a primary goal for potato chip manufacturers. Companies have installed
safeguards at various points in the manufacturing process to decrease the chances for breakage.
The heights that chips fall from conveyer belts to fryers have been decreased. Plastic conveyer
belts have been replaced with wide mesh stainless steel belts. These allow only the larger chips to
travel to the fryers and the smaller potato slivers to fall through the mesh.
Byproducts/Waste
Rejected potatoes and peelings are sent to farms to be used as animal feed. The starch that is
removed in the rinsing process is sold to a starch processor.

26 | P a g e
Conclusion
It was an wonderful learning experience at KISHLAY SNACKS PRIVATE LIMITED for four
weeks in Guwahati. I gained a lot of insight regarding almost every aspect of plant. I was given
exposure in almost all the departments at the plant. The friendly welcome from all the employees
is appreciating, sharing their experience and giving their peace of wisdom which they have gained
in long journey of work. I am very much thankful for the wonderful facility from KISHLAY. I
hope this experience will surely help me in my future and also in shaping my career.

27 | P a g e
References and Resources
I. www.kishlaysnacks.com
II. www.wikipedia.com
III. Operators of machines
IV. Machine Manuals

Internship report on kishlay snacks pvt. ltd. guwahati

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