SUBMITTED BY – SUBMITTED TO –

NAMRATA Mr. Rajesh KumarB.Tech Food Technology, 4th Year JGM, Catering ServicesLady Irwin College, DU IRCTC

ACKNOWLEDGEMENT

The internship opportunity I had with Indian Railways Catering and Tourism Corporation Limited (IRCTC) was a great chance for learning and professional development. Therefore, I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks to Mr. Rajesh Kumar (JGM, IRCTC Central Kitchen), who in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my project at their esteemed organization and extending during the training.

I express my deepest thanks to Mr. Rajesh Kumar (Production Head), Mr. Munandra Kumar (Sr. Microbiologist), Mr. Vipin Nagarwal (Sr. Supervisor, Quality) for taking part in useful decision & giving necessary advices and guidance and arranged all facilities to make life easier. I choose this moment to acknowledge their contribution gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr. Deepak Kumar (Sr. Supervisor, Bakery section), Mr. Sanjeev Pillai (Sr. Supervisor, Sandwich section), Mr. Balwant (Sr. Supervisor, Roti section), Mr. Pappu Chauhan (Sr. Supervisor, Halwai section) and Mr. Gulshan (Sr. Supervisor, Veg/Non-veg section) for their careful and precious guidance which were extremely valuable for my study both theoretically and practically.

I perceive as this opportunity as a big milestone in my career development. I will strive to use gained skills and knowledge in the best possible way, and I will continue to work on their improvement, in order to attain desired career objectives. Hope to continue cooperation with all of you in the future,

Sincerely,

NAMRATAB.Tech Food Technology, 4th yrLady Irwin College, DU

CONTENTS

1. Company Profilea. Preambleb. Missionc. Objectives

2. About Central Kitchena. List of sectionsb. List of equipments/machinesc. List of food items prepared

3. Bakery Sectiona. Soup sticks

4. Roti Section

5. Sandwich Section

6. Veg Preparation

7. Non-veg Preparation

8. Halwai Sectiona. Coconut barfib. Khoya barfic. Kachori

9. Quality Control

COMPANY PROFILE

PREAMBLE

As a part of Indian railways’ wider organizational reform and to strengthen its marketing and service capabilities in the areas of rail catering, touri8sm, hospitality and passenger amenities a corporate entity, Indian Railways Catering And Tourism Corporation Limited (ITCTC)was incorporated on 27th September 1999 under companies act 1956 as a government company to professionalize and manage catering and hospitality services and to promote domestic and international tourism through development of hotels, information and commercial publicity and global reservation system; and to explore and exploit underutilized assets of IR and stimulate private entrepreneurship and investment in the hospitality business; and serve the rail users and passengers through value added services. The company obtained the certificate of the commencement of business on 22nd December 1999.

The full-fledged functioning of the corporation started on 1st August 2001.

MISSION

“To give customer delight in hospitality and travel and tourism industry by best global practices and technology”.

OBJECTIVES

1. To provide all tourism, travel and hospitality related product under one roof by using best industry practices

2. To achieve best practices in hospitality sector and be the no. 1 company in the country in the catering and hospitality

3. To scale the best heights in travel and tourism business and be no1 company in the country

4. To be a customer oriented company through constant innovation, driven by technology and human resource development

5. Optimize resources; increase manpower productivity through quality product/services and innovative marketing strategies

6. Expand areas of core competencies; enhance business opportunities through efficient public-private partnerships

7. Imbibe strong and ethical work culture through team work, build and reposition Indian Railways in the emerging services sector

8. Evolve high standards of business ethics, quality management and effective cost control measures

9. Caring, preserving and improving environment and heritage

ABOUT CENTRAL KITCHEN

The Indian Railway Catering and Tourism Corporation Ltd. (IRCTC) central kitchen is one of the largest kitchens of India. IRCTC has its central kitchen in Noida, Uttar Pradesh that works round the clock in order to provide hygienic, competitively priced and affordable meals to both rail passengers. This state-of-the-art food factory has an optimum capacity of about 25000 meals per day at Sector-64 Noida.

Currently, IRCTC is operating major Base Kitchens at New Delhi and Howrah railway stations and Mini Base Kitchens at Patna and Ahmedabad. The one in Noida is fully automated and has all the latest equipment.

The four-storey facility makes 10,000 meals and 6,000 snack packets for trains. Around 120 workers work in two shifts between 11 pm to 6 pm for the next day to supply the ever-increasing orders.

The kitchen is well-equipped with high degree mechanization from around the world, they have someone from Germany to dice and shred vegetables, while the Finn one boils rice and dal and a France sauté sabzi. And they all work under Indian cooks and managers. While fresh vegetables are straight away dipped into Italian machines that clean them properly, the German cutting machines take over, which run through 400 kg vegetables in an hour.

Simultaneously, workers pack dals and vegetables in insulated containers, and dispatched in temperature-controlled vans to the railway station kitchen for final packaging. Also, rotis are dabbed with butter and rolled in foil to keep them soft for hours.

This IRCTC kitchen makes approximately 6,000 salty snacks and sweets of equal numbers every day, which includes bread sticks, kachoris, barfis and gulab jamuns.

Though they work at lightning speed, compromise in quality is not allowed. They check samples from each and every batch and if anything is found wrong, immediately the entire batch is recalled.

LIST OF SECTIONS –

1. Basement Receiving unit Microbiology lab Vegetable washing area Store Room (raw materials) Store Room 2 (packaging materials) Cold room

2. Ground Floor Vegetable Cutting area Veg Preparation

Non-veg Preparation Packaging Section (Sweets, Kachori, Soup sticks) Pot Wash

3. First Floor Halwai Section Roti/Paratha Section Veg cold kitchen Veg chiller Bakery section IT room Sales department F&B control

LIST OF EQUIPMENTS/MACHINES –

1. Brat pans2. Steam Kettle3. Electric Kettle4. Dough kneader5. Roti Making Machine6. Grinder 7. Chiller8. Form Fill and Seal Machine (Sugar and Creamer)9. Chopper10. Slicer11. Pulplizer12. Rotatory Oven13. Proofer14. Sheet Cutter15. Sheet Machine16. Mixer17. Muffle Furnace18. Fume Hood19. Laminar Air Flow20. Incubator21. Autoclave22. Colony counter23. Microscope24. Hot air oven25. Water Bath 26. pH Meter27. Refrigerator28. Distillation Machine29. Centrifuge30. Magnetic Stirrer31. Rotatory Shaker32. Desiccator33. ETP Plant34. Organic Digester

LIST OF FOOD ITEMS PREPARED –

1. Lunch and dinner (Different Menu)

2. Bread

3. Rice

4. Kachori

5. Sweets – Khoya barfi, Coconut barfi, Gulab Jamun

6. Soup sticks

7. Sandwiches

BAKERY SECTION

SOUP STICK

Ingredients (for 1 Kg) – Ajwain 4 g Bread Improver 1 g Dalda 20 g Refined Oil 5 g Salt 15 g Sugar 20 g Yeast 5 g Calcium Powder Pinch Water 500 l

Process –

Sieving, Mixing and Kneading of all Ingredients (5-7 Mins Slow then 4 mins fast mixing)

Pressing in Machine

Setting in Machine (6.2 mm thickness)

Cutting of dough and rolled to desired length

Dough is kept on plate in machine and it is cut according to the width of the soup stick

It Set on trays (35 long strips) and cut into 3 parts

Proofing for 10-15 mins

Trays are set in the oven and baking is done at 200 C for 30 mins⁰

Trays are taken out and left undisturbed for 10-15 mins

Packaging in stamped wrappers and sealing and then storing in storage room

AFTER BAKING THE WEIGHT OF 1 SOUP STICK IS 10 G, PER TRAY 100 SOUP STICKS APPROX.

ROTI SECTION

ROTI MAKING MACHINES ARE USED FOR PREPARATION OF ROTI

Ingredients – Whole wheat flour 50 g Water 30 g Milk 5 l Refined Oil 1 l

Process –

Sieving, Mixing and Kneading of all Ingredients

Kept over the inlet of roti making machine

Balls of dough comes out og the dough cutter

Balls are shaped by hands (each ball should weigh 35 g)

Balls are kept on the inner circle and pressed by a piston to form roti

It is then shifted to outer circle

Heat is applied and the dough is cooked at 200 C⁰

Cooked roti comes out

Butter is applied manually and packed in aluminum foil

SANDWICH SECTION

VEG SANDWICHES ARE PREPARED

Ingredients – Bread (shelf life – 4days, stored at 2-4 ⁰C) Carrot Cabbage Mayonnaise (Best foods) Salt Black pepper Powder

Process –

Chopping of all vegetables

Addition of salt to carrot and cabbage and left undisturbed for sometime untill water is removed

Pressing is done in muslin cloth to remove water

Filling prepared: Carrot + Cabbage + Salt + Black pepper Powder + Mayonnaise

With the help of knife filling is applied on the bread slices

Cutting of the edges of the bread

Manual Packaging done

Sticker with shelf life sticked

AFTER PACKAGING, VEG SANDWICHES ARE STORED IN COLD ROOM

VEG/NON-VEG SECTION

STEAM KETTLE:

1. Used for preparation of rice & soup.2. Maintained at a temperature above 70°C3. Electrically operated4. Inner wall of the kettle is hot, whereas the outer wall is not that much hot ( to avoid

burning)

BRAT PAN:

1. Used for preparation of dal, curry, dry vegetable2. Two type:

Gas operated- runs on PNG; more efficient Electrically operated

3. Temperature is measured using digital thermometer.4. Continuous mixing should be done so that even temperature is maintained.

RICE PREPARATION –

Water is poured in the kettle

Boiled till it reaches boiling temperaute

Rice is put up in kettle

Rice is cooked in it (kettle is left open)

Water is drained out by attachng a mesh and inverting the kettle

Rice sent to cold room in big containers

In cold room, rice is spread on table for cooling to remove rice lumps.

SOUP PREPARATION –

Receiving of raw materials (vegetables, oil, maida, spices, cream, etc)

Washing of vegetables

Peeling, chopping, cutting, boiling, etc. of vegetabes

Preheating of oil, addition of onion, spices, puree and sauteing

Boiling of soup

Maida frying, water addition & boiling with stock

Addition of salt, pepper, sugar

Straining, pouring in containers

Dispatch

HOT SERVE CURRY PREPARATION (VEG/NON-VEG)-

Receiving of raw materials

Washing of vegetables, dal, non-veg item; soaking & thawing

Peeling, chopping, boiling, etc

Pre-heat of oil, addition of onion, spices/seasoning & sauteing

Addition of chicken/ vegetables/ dal & cooking like frying, sauteing, curry preparation

Holding

Packing & dispatch

HALWAI SECTION

1. Coconut barfi

Ingredients –

Sugar syrup ( 100°C or higher) Desiccated coconut (ground) Food grade color

Process –

Receiving of materials

Sorting of materials

Addition of sugar syrup to ground coconut

Mixing (maually)

Left covered & undisturbed for 30 minutes

Mixing in dough kneader

Spread on trays

Setting in oven (120°C-150°C/ 20 minutes)

Cover the trays for sometime

Kept undisturbed for sometime

Cutting of barfi (knife is sanitized with 150ppm chlorine)

Packing & dispatch

2. Khoya barfi

Ingredients –

Sugar syrup ( 100°C or higher) Khoya

Process –

Receiving of materials

Sorting of materials

Addition of sugar syrup to Khoya

Mixing (maually) on heat

Left covered & undisturbed for 30 minutes

Spread on trays

Cutting of barfi (knife is sanitized with 150ppm chlorine)

Packing & dispatch

3. Kachori

Ingredients –

Oil Jeera Moong dal Red chilly Salt Hing Besan Coriander powder

Process –

Receiving of materials

Dough preparation

Filling

Frying

Storage & holding

Packing & dispatch

QUALITY COTROL

Quality control is the major aspect in any food inustry as far as health and satisfaction of the consumer is concerned. IRCTC Central Kitchen has a Quality lab dedicated for this purpose exclusivey, where food is examined in three ways:

1. CHEMICAL TESTING: involves test for presence of adulterants in the food materials

2. MICROBIOLOGICAL TESTING: involves various test to acknowledge microbial contamination, food spoilage, etc.

3. PHYSICAL TESTING: Company’s name Date of manufacture Batch no. Expiry date FSSAI certification Weight Packaging, etc.

MICROBIOLOGICAL TESTING

Media used: Violet red bile agar Potato dextrose agar Plate count agar

Process:

Collection of Sample

Sterilization of Equipments in hot air oven (180°C/2 hrs)

Media Preparation

0.9% Saline solution Preparation

Autoclave (121°C/15 psi/15 min)

Cooling

Mix 10g of sample in 90 ml of 0.9% saline solution

Sterilize laminar flow (15 min.)

Prepare Serial Dilutions

Incubate for 24 hrs at 37°C (coliforms & TPC) & for 3-4 days at 28°C (yeast & mould)

Count colonies using Colony counter