how is parle g made?

How is Parle – G made?

Parle G has become the undisputed leader among the biscuits brands in India. In this post, we will have a look at some basics of how our most favorite product is prepared before it reaches our hands. Let us see how is Parle – G made in factories?

How is Parle – G made – Raw Materials – Recipe of Parle – G

Following is the recipe of Parle – G biscuits.

  1. Wheat Flour
  2. Sugar
  3. Invert Syrup
  4. Leavening Agents (503 Baking Powder)
  5. Partially Hydrogenated Edible Vegetable Oils
  6. Salt
  7. Milk Solids
  8. Dough Conditioners (E223) and Added Flavors
  9. Emulsifiers (E322 or E471 or E481).

Step by Step Process of how is Parle – G manufactured?

Following is the diagrammatic presentation of the manufacturing of Parle – G.

How is Parle - G made

The biscuit Parle – G is manufactured at Parle Products Ltd at Vile Parle. Parle buys raw material from its suppliers. The raw material is tested carefully in labs. This raw material is made up of sugar, wheat flour, partially hydrogenated edible veg oils, leavening agents, milk solids, invert syrups, salt emulsifiers, etc. which are listed above. This all raw material mixture is then fed into Stephan Mixture. It is a high power mixing machine that is made to mix the dough and other ingredients. From this machine, the mixture is then taken to a molder which is known as Rotary Moulder. This molder has around 260n cups which give the biscuit their famous familiar shape and the Parle – G impression embossed on every single biscuit.

Manufacturing Process of Parle – G: Stages Involved in Manufacturing of Parle – G

Now the next step is to transfer the dough from the mold into an oven, which is 260 feet long at 340° C. The oven process is followed by the following steps:

  • Moisture Removal
  • Biscuit structure building
  • Biscuit coloring

Now, from the oven, the biscuits are transferred to a Cooling Conveyor, and the biscuits are allowed to cool down for around 6 to 7 minutes so that the remaining moisture may go dry. And that’s how there is an S Flow Layout in the manufacturing unit.

The conveyor keeps on moving and reaches to Counting Unit. As the name suggests, the biscuits are counted here and are cross-examined if all is working fine or not. The biscuits move to the Stalking Table where the biscuits are packed in the same manner. From the table, the biscuits are taken to the Multi-Pack Wrapping Machine which packs 16 packs in one go and the weight comes up to 100 gms. A total of 24 packs is packed in a polybag and then sent to Sealing Machine to seal it airtight. From here, these are moved to  Corrugate Box Section where the bags are put in the boxes and are then sent to the Dispatch Section via the conveyor. And the biscuits are ready to be sent all across the country.

Flow Chart – How is Parle – G made?

Pre Mixing Stage

  • Addition of Ingredients
  • Sugar Solution
  • Milk Solution
  • Flour Preparation
  • Fat, Ammonia, Additives
  • Flour sifters sugar grinders

Mixing Stage

  • Mixers
  • Mixing Time
  • Water
  • Creaming
  • Dough Consistency
  • Biscuit Grinders

Forming Stage

  • Laminators
  • Gauge Rolls
  • Sheet Reduction
  • Cutter
  • Molders
  • Shape and size of Dough pieces

Baking Stage 

  • Baking Ovens
  • Baking Time
  • Temperature
  • Burners
  • Steam Extraction
  • Oven Output

Cooling Stage

  • Cooling Time
  • Cooling Conveyor

Packaging Stage

  • PPM
    Metal Detection
  • Stackers
  • Feeding Chute
  • Horizontal Flow from Wrap
  • Vertical Filling
  • Cream Sandwiching
  • Wrapper
  • Printing
  • Carton Sealing

Process of Making Parle – G

How is Parle - G made

The process discussed above the same which is used in Parle – G manufacturing factories. Hope that you have come to know how is Parle – G manufactured?

 Click here to read about nutritional value in Parle G

 

How Parle-G Is Manufactured: A Detailed Technical Breakdown

Parle-G is one of the most mass-produced biscuits in the world, requiring precision engineering, food chemistry, and industrial automation to maintain consistency at a staggering scale. Let’s dissect every aspect of the manufacturing process—from ingredient chemistry to mechanical engineering behind biscuit production.


1. Raw Material Composition & Pre-Processing

Parle-G’s ingredients are selected based on specific molecular properties to ensure the desired texture, crunch, and shelf stability.

Ingredient Chemistry & Functional Role

IngredientChemical CompositionPurpose in Biscuit Making
Wheat Flour (Maida)8-12% protein (mainly gluten), 70-75% starch (amylose + amylopectin), 12-14% waterProvides elasticity & structure, allows gluten network formation.
Sugar (Sucrose + Glucose Syrup)C₁₂H₂₂O₁₁ + C₆H₁₂O₆Adds sweetness, caramelization, affects moisture retention & Maillard reaction.
Edible Oils (Palm Oil, Vanaspati Ghee)Triglycerides, mainly palmitic (C16:0) & oleic acid (C18:1)Provides flakiness, improves shelf life, prevents staling.
Leavening Agents (Baking Soda + Ammonium Bicarbonate)NaHCO₃ + NH₄HCO₃Releases CO₂ during baking, forming air pockets, making biscuits light & crispy.
Milk SolidsCasein (α, β, κ-caseins), lactose (C₁₂H₂₂O₁₁)Adds flavor, protein structure, and enhances Maillard browning.
Salt (NaCl)Sodium chlorideEnhances flavor, gluten network strength.

Pre-Processing: Ensuring Ingredient Consistency

  • Flour Handling:
    • Passed through high-speed vibratory sifters (1200 rpm) to remove clumps and aerate the flour.
    • Moisture content adjusted (12–14%) using industrial desiccant drying systems.
  • Sugar Pulverization:
    • Sugar crystals undergo micronization in hammer mills to achieve <200-micron particle size.
    • Glucose syrup is heated to 80°C to ensure consistent viscosity.
  • Oil Conditioning:
    • Palm oil stored in insulated tanks (35–40°C) to prevent crystallization.

2. Dough Mixing: The Science of Structure Formation

Dough is mixed in vertical planetary mixers equipped with programmable logic controllers (PLCs) to maintain:

  • Shear force optimization (to prevent overdevelopment of gluten).
  • Exact ingredient proportions (controlled via load cell-based mass flow meters).

Mixing Sequence & Parameters

StepTime (min)Speed (rpm)Key Reactions
Dry Mixing2–360Flour + sugar + salt + leavening agents uniformly distributed.
Oil Addition3–580Lipids coat flour particles, limiting water absorption.
Water & Milk Addition4–6100Gluten matrix starts forming; enzymatic activity begins.
Final Kneading6–8120Dough becomes elastic; Maillard precursors develop.

Critical Process Controls:
Dough temperature must not exceed 30°C (prevents premature gluten degradation).
Moisture content adjusted to ~20% (ensures spreadability).
Leavening gas entrapment optimized (affects biscuit density).


3. Sheeting, Cutting & Molding: Mechanical Engineering of Biscuit Shaping

Once mixed, the dough is passed through multi-stage sheeting rollers with:

  • Roller clearance precision: ±0.01 mm
  • Pressure-controlled extrusion to maintain uniform thickness

Rotary Cutting & Embossing

  1. Dough Sheet Formation:
    • Passed through calibrated stainless steel rollers at 300 rpm.
    • Final sheet thickness: 2.8–3.2 mm.
  2. Embossing & Cutting:
    • High-precision CNC-machined rotary dies cut biscuits into their signature shape.
    • Waste dough is automatically recirculated to prevent loss.

4. Baking: The Thermodynamic Transformation

Parle-G biscuits are baked in continuous tunnel ovens (250+ ft long) using gas-fired infrared heating elements.

Thermal Profile & Chemical Changes

Oven ZoneTemperature (°C)Key Reaction
Preheat Zone180–200Water evaporation starts, gluten network solidifies.
Expansion Zone230–250Leavening agents decompose, CO₂ + NH₃ released, biscuit expands.
Browning Zone180–190Maillard reaction & caramelization create color + flavor.
Final Drying140–150Moisture reduced to <5%, stabilizing crispness.

Reaction Highlights:

  • Baking Soda (NaHCO₃) → Na₂CO₃ + CO₂ + H₂O
  • Ammonium Bicarbonate (NH₄HCO₃) → NH₃ + CO₂ + H₂O
  • Maillard Reaction: Reducing Sugars + Amino Acids → Brown Color + Aroma Compounds

Total baking time: ~4 minutes per batch.


5. Cooling & Quality Control: Precision Analysis

After baking, biscuits must be cooled in a controlled environment before packaging.

Key Cooling Parameters:

  • Cooling Conveyor Speed: 15–20 m/min
  • Airflow Velocity: ~1.5 m/s
  • Target Exit Temperature: 35–40°C

Quality Checks Performed:

Moisture Analysis (must be <5% for crispness).
Weight Check: Each biscuit weighs 5.5 g (±0.1 g).
Color Uniformity Scan: Using RGB spectrophotometers.
Break Strength Test: Ensures crispiness without excessive brittleness.


6. Packaging & Logistics: The Final Engineering Feat

Parle-G biscuits are packed in automated high-speed flow wrap machines, with:

  • Sealing Temperature: 110–120°C (to ensure airtight packaging).
  • Nitrogen Gas Flushing: Reduces oxidation, extends shelf life.
  • Barcode & Expiry Date Printing: Laser-engraved for accuracy.

💡 Production Speed: Each factory produces ~4,000 packs/min.
🚛 A new Parle-G truck leaves every 30 seconds!


Conclusion: The Engineering Marvel of Parle-G

Behind every simple pack of Parle-G lies precision chemistry, cutting-edge automation, and industrial-scale production mastery.

Ingredient selection is molecularly optimized.
Machines operate with ±0.01 mm precision.
Each biscuit undergoes over 20 quality control checks.

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