ZUBIX INTERNATIONAL LIMITED PRODUCERS OF
ZUBIX CHEESE BALLS, BISCUITS, CORNFLAKES, LEMON SWEETS, AND ALLIED PRODUCTS,
LOCATED AT OGIDI, ANAMBRA STATE.
SUBMITTED TO
THE DEPARTMENT OF FOOD SCIENCE AND
TECHNOLOGY, FACULTY OF AGRICULTURE AND NATURAL RESOURCES MANAGEMENT
IN PARTIAL FULFILLMENT OF THE AWARD OF
BACHELOR OF SCIENCE (B.Sc) FOOD SCIENCE AND TECHNOLOGY (F.S.T)
TABLE OF CONTENT
Table
of content
Chapter one
Introduction
Chapter two
Brief
history of the company
Chapter three
Description
and history of cheese balls
Chapter four
Processes
in cheese balls production
Chapter five
Methods
of cheese balls storage
Chapter six
Challenges
encountered
Chapter seven
Conclusion
and recommendation
References
CHAPTER ONE
INTRODUCTION
The student’s industrial experience
is a welcomed skill training programme which forms parts of the approved
minimum academics standard in various degree programmes for all the Nigerian
Universities.
It is an extortion to bridge in the
gaps existing between theory and practices of engineering and technology
science, agriculture, medicals, managements and other professional educational
programmes in the Nigerian tertiary institution. It is aimed at exposing
students to machines and equipment, professional work methods and ways of
safeguarding the work areas and workers in industries and other organization.
The minimum duration of the SIWES
(Student Industrial Work Experience Scheme) should normally be 24 weeks (6 months)
which excludes engineering and technology programme. Where the minimum duration
is 40 weeks the scheme is a tripartite programme involving the students, the
Universities and the industrial (employer of labour of Nigerian and jointly
co-ordinated by the industrial training fund (ITF) and national Universities
commission (NUC).
OBJECTIVES OF SIWES
The
objectives of the students industrial work experience include the following:
- Provides
the student for the work situation that they are likely to meet after
graduation.
- IT
prepares the students, in terms of employer’s involvement in the entire
educational process of preparing Universities graduates for employment in
industry.
- It
helps in making work easier and enhancing student’s contacts for later job
placement.
- It
helps to acquire students of Nigerian in their industrial skills and experience
in the course of study.
- It
helps students to handle equipments and machinery that may not be present in
the school.
CHAPTER TWO
BRIEF HISTORY OF THE COMPANY
Zubix International Nigerian
Limited, is a known experienced production industry situated at Ogidi in
Anambra State, Nigeria.
The company is responsible for
supplying of Zubix cheese balls, Zubix biscuits, Zubix cornflakes, Zubix lenon
Sweets and allied products to almost the south, east, west of Nigeria.
The company Zubix International
Nigeria limited was established in 1985 by Chief Azubuike. A. Okafor of Alor,
in Anambra State.
The company Zubix Nig. Limited is
also a registered company with National Agency For Food and Drugs
Administration (NAFDAC) with the registration number of AI-5788.
The company which is located at
Ogidi in Anambra State has sufficient boreholes, water tanks, buses which helps
them carry out their work in the factory.
The company also produces table
water and sachet water which is known as vivia sachet and table water.
Organization structure of the company
Zubix International Nigerian Limited
has many department and staff in the company. Some are grouped as casual
workers while some are grouped as main staff.
The section includes chemical room,
production room, packaging room, sealing section, marketing department and the
ware house.
The Organogram for Zubix Nig. Limited
This is a sample: Contact Us to get
the Organogram
PRODUCTION CAPACITY
Zubix Nigerian Limited, Produces an
average number of 20,000 bags of cheese balls per day which comprises of
morning workers and night workers.
In the production of cornflakes,
there produces an average of 10,000 cartoons of corn flakes which is known as
Zubix corn fakes per day, Zubix Danish cookies are also produced 10,000
cartoons per day, Lemon Candy of 2000 cartoons per day etc.
SET BACK FACED BY THE COMPANY
1. High cost of raw material in Nigerian.
2. Power failure
3. Emergency
breakdown of some machines during working periods.
CHAPTER THREE
DESCRIPTION AND HISTORY OF CHEESE BALLS
Cheese balls which is also known as cheese
puffs, Cheese curls, are a puffed corn snacks food which is coated with a
mixture of cheese flavored powders.
Cheese balls is a popular snack which is
known in most countries especially U.S.A , Canada & Nigeria. Cheese balls are manufactured by
extruding heated corn through a die that forms the particular shape of balls,
curls etc.
Cheese balls are of different shapes
which may be ball-shaped curly (“cheese curls”), straight or irregular shape as
animal or other objects.
Some cheese balls are puffy, while others
are crunchy.
However, cheese balls can be served with milk;
it can be eaten at all time. Cheese balls are taken by everyone especially
little children who take it to school as snacks.
Cheese balls which is a very good sources
of protein, vitamin with fat and oil . it is a snacks for all ages and all times,
which can be taken at schools and picnics.
RAW MATERIALS FOR CHEESE BALLS
PRODUCTION AND THEIR FUNCTIONS.
- Maize grit
- Milk flavour
- Food colour
- Water
- Vegetable oil
- Aspartame
- Salt
- Citric acid.
FUNCTIONS:
1. MAIZE
GRIT
Maize
(Zea Mays) is a cereal grain. Maize grit which are cereals are rice sources of
starch and contains from 7:14% protein.
The protein of cereals are deficient
in the essential amino acid lysine. Maize grit is made with yellow or white
corn, which is a good source of vitamin A and E.
In the production of cheese balls,
maize grit is the main ingredient because it is the most important raw material
for the production of cheese balls. Maize grit is gotten from corn, which can
be grinded in a powdered form to form maize grit.
Maize grit is a good source of
carbohydrate, but contains protein and vitamin in a trace amount.
2. MILK
FAVOUR:
In cheese balls production, milk
flavour is very important because it improves and gives taste to food (Cheese
balls).
Milk flavours
are usually into diary products to elevate their taste and mouth feel.
Dairy products and food with milk flavours have always
been popular with customer. Therefore in order to satisfy customer’s
requirements for taste. Milk flavour is added to develop and enhance the taste
of any food.
Snacks
which contains milk flavour is been taken by children because of its milky
flavoured aroma and it makes customers buy them.
A good milk flavour is a very good source of calcium,
protein, vitamins D, Vitamin A, Vitamin B12, Phosphorus and niancin.
3. FOOD
COLOURING:
Food colouring is any agent that is
added to enhance color or visual appeal of a food or drink.
Food colouring is derived naturally
from various flowers, spices or food or can be artificially or chemically
created.
Food colouring agents are tasteless
so do not change the taste of food.
In the production of cheese balls,
food colouring is used to enhance the colour of the food. Food colour is used
to mask colour variation in a food, to identify a food, for decorative
purposes, and to make it appetizing.
Food colouring comes in liquid, gel,
paste and powder form. The liquid form is the most common, and typically
provides the weakest colour.
Food colouring is good in the
production of cheese balls to make it appetizing and palatable.
4. WATER
Water is a universal solvent,
potable water is need for cheese balls production.
Water helps to obtain dough of good consistency.
It is an essential ingredient in cheese balls production, it also helps in
achieving homogenization, hydration of glaidin and glutenin (Protein of flour)
to form glutein.
Water acts as solvent for dry
ingredients such as salt, sugar and it is particularly important for the
reaction of chemical leavening agents.
During the production of cheese
balls, the quantity of water needed varies with the quantity of the maize grit.
5. VEGETABLE
OIL:
Vegetable oil are lipid materials
derived from plants. Physically, oils are liquid at room temperature and fats
are solid chemically, both fats and oils are composed of triglycerides, as
contrasted with waxes, which lacks glycerin in their structure.
Although many plants yield oil, in
commercial practice oil are extracted
primarily from seeds.
Vegetable oil are derived from
canola oil, soy bean oil, corn oil, etc. vegetable oil is very important in the
production of cheese balls production, because it binds the ingredients
together, and helps the texture of the dough (corn grits) to be soft while taking
or consuming vegetable oil is a very good source of energy and it supplies
essential fatty acids.
6. ASPARTAME
Aspartame which is also known as
nutra sweet is a sweetening agent. Aspartame which has been in the market since
1981.
Aspartame which originated from
U.S.A is a sweetening agents which is composed primarily of two common amino
acids, aspartic acid and phenylalanine, which is a building block for
conventional food such as protein and natural flavour molecules.
Aspartames which are used n the production
of diet soda drinks, foods, beverages etc. it is very good in the production of
food because of its Iower calorie.
In the production of cheese balls,
we use Aspartame because it improve the taste of cheese balls giving it that
sugar taste and making it palatable to eat. Aspartame is a good source of
Vitamin A.
7. SALT:
Salt improves the taste of food. In
the production of cheese balls, salt brings out more flavour and sweetness in
them.
8. CITRIC
ACIDS:
Citric acid is one of the beneficial
ingredients in the production of cheese balls. Citric acid is an organic acid
but not to be confused with Vitamin C, which is ascorbic acid. Citric acid
helps prevents urinary tract infection, aids in the removal of toxins from the
body etc.
CHAPTER FOUR
PROCESSES IN CHEESE BALLS PRODUCTION
Cheese balls is made wit six basic
ingredients; namely maize grit, water, milk flavour, aspartame, food colour and
vegetable oil and also other optional ingredients include salt and citric acid.
These when mixed in a mixer for
about 3-5 minutes will give a homogenous mixture.
Cheese balls production involves
various processes and stages which includes the following:
- Collection and inspection of raw
material
- Measurement
- Mixing
- Extrusion
- Baking
- Flavouring
- Packaging
- Warehousing etc.
The unit operation in cheese balls production
PROCEDURES IN CHEESE BALLS PRODUCTION
PROCESS
Collection and Inspection of raw materials
All the raw materials for cheese
balls production are carefully collected from the chemical room where it is
tested to determine the quality of a good product.
Measurement: To achieve desired quality at the end of production,
both compulsory and optional ingredients are measured in their proper
proportion. Weighing and measuring of ingredients are very vital as inaccurate
measurement of result could lead to undesirable and low quality of cheese
balls.
Mixing: Mixing process is critical to the quality of the final product. It
helps to achieve consistency and homogeneity of the ingredients. In the
production of cheese balls, all the raw materials which include maize grits,
food colour, flavouring, aspartame, salt, vegetable oil, water and citric acid
are mixed together in a mixer for about 3-5mins before production.
The standard mixing procedure and
ingredient weight quantity are as follows:
|
Ingredients
|
Weight (kg)
|
|
Maize
grits
|
300kg
(6 bags)
|
|
Milk
flavour
|
40kg
|
|
Food
colour
|
100kg
|
|
Water
|
300cl
|
|
Vegetable
oil
|
2
litres
|
|
Aspartame
|
50kg
|
|
Salt
|
5
Kg
|
|
Citric
acid
|
10kg
|
All these are mixed using electric mixing
machine which is known as mixer. The mixer is made of stainless steel and this
prevents rusting which is capable and able of recontamination of the homogenous
mixture.
Extrusion: Extrusion is the process by which the balls are
produced. Extruder is a machine which conveys the maize grit mixture to the
hoper of the extruder with the help of plastic conveyor.
i. Hoper: it is a stainless container or
a bucket which is temporary used for the storage of grit mixture.
Baking: It is a treatment process that involves the heating of the cheese
balls in the oven at a certain regulated temperature. The baking range
temperature is 190oc at a speed of 150RMS.
This baking process makes the cheese
balls to have a crunchy taste while eating. At this stage the moisture in the
cheese balls is being dried and ready to consume.
Flavouring: Flavouring is a very necessary and important process
in cheese balls production. The raw materials for flavouring includes cheese
flavour, salt, vegetable oil.
Flavouring is the process that
involves mixing the cheese flavour, salt and vegetable oil together. This makes
the cheese balls to look appetizing and attractive for the consumers
|
Ingredients
|
Weight
|
|
Vegetable
oil
|
80
liters
|
|
Food
colour
|
100kg
|
|
Salt
|
10kg
|
Packaging :
The properly flavoured cheese balls
are manually packaged using a nylon bags. This is to protect the cheese balls
against micro-organisms, moisture, air and other forms of contamination. And it
also helps in easy handling and transportations of the cheese balls.
Ware housing and marketing:
The properly sealed sachets of
cheese balls are manually packed in the storage room/ ware house awaiting
sales. Some customers come to the factory to purchase their cheese balls, but
is mostly transported to customers who wants to buy in bulk, using Lorries,
pickup etc. the properly sealed cheese balls are packed 100 sachets in a nylon
bag.
CHAPTER FIVE
METHODS OF CHEESE BALLS STORAGE
Inefficient methods of storage and
rough bad handling of cheese balls can lead to breakage of the cheese balls. A
good storage method includes the following:
(1) To extend the shelf life of the cheese
balls
(2) To retain the initial taste and flavour
of the cheese balls
(3) To retain the textural quality of the
cheese balls
Good
method of storing cheese balls includes the following:
(a) Storing the cheese balls in air tight
nylon bag.
The storing method helps in
preserving the freshness of the cheese balls. Since cheese balls can be soft if
not tighted well, the plastic bags / nylon can help to avoid air.
(b) Store in a cool place to avoid air
spoiling it and making it soft.
(c) Avoid throwing the bags while loading or
at any time to avoid breakage
STALING:
It is a common knowledge that when
cheese balls are stalled for a very long time, it becomes soft and crunchyless. This could be due to air.
Stalling
reduce she palatability of cheese ball and makes it tasteless while eating /
consuming.
To maintain the freshness of the
cheese balls, it should be kept at a room temperature of 600c.
CHAPTER SIX
Firstly, finding a place of
attachment was not really easy for me but God by my side, I was able to find a
place. I met a lot of challenges which involved asking me my state, my school
and so many things. At a point I was
confused but is had to pick up courage and continue trying my luck, one day as
I went to church at our Lady’s of Victory Catholic Church Umuleri, I bought the
trinitas (Catholic News Paper) reading it I found out that there was a company
which produces cheese balls, biscuits etc I called the number at the back of
the paper but it was not going, I have to pick up courage to go to the company
as I have the address of the company
with me, which I got from the news paper. It only took the grace of God for me
to get that Job.
Secondly at the initial stage of my
training, I found out that cheese balls production wasn’t easy, I was managing
myself and was still trying to fit in myself in the work. At last I noticed I
could be of a great help for the company because of their production capacity.
We have many customers, so there was no amount of biscuit, cheese balls,
cornflakes, lemon candy produced daily that was enough for customer. Therefore,
to meet up with our customers demand we have to work morning and night to meet
up with our customer.
Finally, cheese balls machine are
not found in Nigeria because it’s not movable, the machines are noiseless and
very fast in production.
RECOMMENDATION
Based
on my experience during the six months of industrial training the following are
my recommendation
(1) Government
at all level should ensure that electricity are taken properly cared off.
(2) Proper
funding of the manufacturing sector of the economy by the government.
(3) Companies
/ factories especially cheese balls, corn flakes, biscuits and sweet companies,
should mandate the use of Lab Coat, by staff in their work place.
(4) Government
should make sure that NAFDAC officials are always going to production companies
to maintain good products.
(5) Federal
government should make it mandatory for all ministries, companies, and
government agencies to offer attachment places to students in their relevant
field of study, so as to forestall the rate at which students suffer on the
course of finding a place of Industrial attachment.
CONCLUSION:
Zubix Nigeria Limited gave me the
privilege of learning about production. “experience they say is the best
teacher” I can’t imagine how my life is going to be after graduation without
this industrial training which has given me a lot of experience in cheese balls
production, sweet production, cornflakes production and biscuit production. I
want to say a big Thank You to Ebonyi Food Science and Technology lectures for
making sure that every students goes for an industrial training.
I promise myself that one of my
daughters is going to read food science and technology to its greatest highest
REFERENCES
Deirdres S. Blanchifield, How Cheese products are
made: An illustrated Guide to product manufacturing, gale, 2002, ISBN NO –
7876-2444-6, P. 70.
Stuart, Elliott (14 July 2011) “Celebrating south Park
by bring it to life” The New York Times. Retreved 19 October 2011.
Burtea, O (2001). Snack Foods From Formers and high Shear Extruders” in
Lusas EW; Rooney Lw. Snack foods processing. PP. 287 ISBN 1- 56676-932 -9.
“ U.S Patent 2, 295, 868”