BUREAU OF INDIAN STANDARD (Central Marks Department-1) Our Ref: CMD-I/3: Subject: Preparation of Sectoral Manuals

Transcription

1 BUREAU OF INDIAN STANDARD (Central Marks Department-1) Our Ref: CMD-I/3: Subject: Preparation of Sectoral Manuals 1. As per the directions of DG, work related to preparation of Sectoral Manuals for identified subjects was awarded to retired BIS officers after the designated committee had approved their names. 2. Annexure I give the names of Ex-BIS Officers who have prepared the Draft Manuals and submitted for consideration of BIS. 3. Nine such Manuals are attached here with for perusal of all concerned. 4. All are requested to kindly go through these Draft Sectoral Manuals and forward comments to respective CMD-2/3 latest by 15 January 2007 for further examination, modifications and finalization. (P.K.Batra) Sc F &Head(CMD-I) Enclosed: as above (9 Manuals) D&H (ITSD): with a request to host the attached documents on Intranet for information of all concerned. Cc: D&H (CMD-2) and D&H (CMD-3): with a request to finalize the Sectoral Manuals as per enclosed details after receipt of feedback from all ROs/BOs under intimation to CMD-1 for processing of payment as per agreed terms and conditions.

2 Annexure-1 DRAFT SECTORAL MANUALS Sl. Name No. 1. Shri S.K. Dasgupta Flat 1 E, Sheetal Chaya Apartment VIP Road, P.O. Ashwani Nagar Baguiati Kolkata Scope of Awarded work Biscuits (IS 1011) 1 MANUAL Co-coordinator details Shri S.K. Chaudhuri, Scientist E, MDK-3, Kolkata Phone: Remarks Draft Manual received (1) Phone: Shri Nilmoni Mitra 403 Udaigiri Apartment Kaushambi Housing Project Ghaziabad Ph: Rolled Steel Products (Sheets) (IS 277,, 513, 648, 1029, 1079, 1993, 2002,, 10748) Shri B.K.Shreevastava, Scientist E, GZBO, Ghaziabad Ph: Draft Manual received (1) 1 MANUAL 3. Shri U.N. Putatunda 804 Kanchanjunga Kaushambi Ghaziabad Ph: Mob: Steel Pipes, Tubes and Fittings (IS 1161, 1239(Pt. 1&2), 1978, 3589, 3601, 4270, 4923, 5504, 6392 and 9295) Shri C.K. Veda, D&H (MED), BIS HQ Ph: Draft Manual received (1) 1 MANUAL 4. Shri P.Rabindranathan, Kumaramangalath House Panangad,Kodungallore Thrissur,Kerela Mob Ph: Natural Rubber and Natural Rubber Latex ( IS 4588 and 5430) 1 MANUAL Shri U.K. Anabrasu, D&H, TBO, Thiruvananthapuram Ph: Draft Manual Received(1) 5. Shri M.S. Nagaraj D-201, 2 nd Floor Purva Pavilion 25/2 Hebbal Kempapara Road UPVC Pipes (IS 4985, 7834, 10124, 12818, 13592) Sh Sadasivam, Sc E Bangalore Draft Manual received for 1 out of 3 manuals (UPVC Pipes)

3 Hebbal, Bangalore Ph: Mob: HDPE Pipes (IS 4984, 14333) Polythene Pipes and fittings (IS 12786, 13487, 13488, 14151) Ph: MANUALS 6. Shri R.K. Monga B3/85-B, Lawrence Road,Delhi rajmonga@hotmail.com Mob: Ph: Electric iron &Electric radiators + Electric Immersion water heaters and Geysers (FOR PERFORMANCE AND SAFETY REQUIREMENTS) Sh. Ghanshyam Jha, Director MDD-2 BIS, New Delhi Ph: Draft Manual received for Electric Radiator (1 out of 4 identified products). 2 MANUALS 7. Shri M.A.U. Khan, 122, Sidhartha Enclave, Ashram, New Delh Ph: LPG Burning Appliances (IS 4246, 4760 and 11480) 1 MANUAL Sh. S.D. Dayanand, MDD-1 BIS New Delhi Ph: Draft Manual Received (1) 8. Shri R.K. Dua Ex. DDG, BIS Flat No. 22 A, Pocket BW, DDG SFS Flats, Shalimar Bagh Delhi Ph: Shri N.S. Vijayaraghavan, Saroj, Ist Floor, 5,7 th Cross, Krishnappa Block, Ganga Nagar Extn. Bangalore Jute & Jute Products (IS 1943, 2566, 2818 (Part 2), 3984, 7406 (Part 2), 12650, 15138) 1 MANUAL Wire Ropes 1 MANUAL Sh. P. Bhatnagar Director TXD BIS New Delhi Ph: Sh Prasada Reddy Sc E BNBO Bangalore Draft Manual Received(1) Draft Manual Received(1). Ph: Mob: yenesvee2000@yahoo.com Ph: Mob: For BIS Use Only Doc No.:

4 Date of Issue: MANUAL FOR BISCUITS (First Issue) BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI CONTENTS SECTION No. PAGE No. TITLE PAGE 1 INDEX PAGE 2

5 1. FOREWORD 3 2. PRODUCT DESCRIPTION 4 3. SPECIFICATIONS & HYGIENE EQUIREMENTS 6 4 MANUFACTURING PROCESS & CONTROLS 8 5. CERTIFICATION CRITERIA 11 ANNEXURES: I. LIST OF TESTING FACILITIES REQUIRED AS PER IS 1011: 2002 II. GUIDELINES FOR ASSESSMENT OF HYGIENIC CONDITIONS III. MANUFACTURING PROCESS FLOW DIAGRAM IV. SCHEME OF TESTING & INSPECTION FOR IS 1011: 2002 V. GUIDELINES FOR STOP MARKING OF BISCUITS Page 2 SECTION 1 FOREWORD BIS has published an Indian Standard on Biscuits namely IS This standard covers all the different varieties of biscuits covering sweet, salted, filled and coated biscuits. The product is under voluntary certification. The Standard was first published in the year Since then the standard has undergone 3 revisions and the current version has been implemented with effect from 15 June Though the standard was first published long back, the absence of any specific documented guidelines regarding operation of the certification schemes for the product, different approaches were followed by the different ROs/ BOs, for all these years, thus leading to confusion amongst the Marks Departments of the Bureau. Hence a strong need was felt for formulation and implementation of a Sector Specific Manual for ensuring uniformity in operation of the certification schemes for biscuits.

6 This Manual provides General Guidelines on various aspects related to certification of biscuits. Efforts have been made to provide suitable explanatory notes, wherever necessary, to the hygienic requirements prescribed in the Standard, to take care of subjective interpretations. It also includes specific proformae for submission of reports of preliminary & periodic inspections so as to facilitate uniform reporting by IOs, covering all essential parameters required to be reported as per ISS and STI. The Manual gives illustrative examples of the process flow diagrams of manufacturing, plant and machinery, cleaning and disinfection of processing areas. IS 1011 specifies the requirements to be tested as per the methods of tests given in the various cross referred standards. This manual provides a ready reckoner for the IOs to check facilities for each of the requirements against the method given under the IS. Various guidelines have been issued from time to time regarding Indian Standard/STI and related certification operational issues. Efforts have been made to incorporate major decisions in this manual, however, the provision of ISS, STI and policy guidelines would prevail over the manual, incase of any difference in interpretation. This Manual is to be used along with IS 1011 and STI amended/revised from time to time. This document is intended for internal use by BIS officers only. Suggestions for any improvement in the manual may be sent to CMD for consideration. Page 3 SECTION 2 PRODUCT DESCRIPTION Biscuits are manufactured from biscuit dough prepared by compounding a mixture consisting primarily of Maida and/or wheat flour, Fat or Bakery Shortening, Sugar and Water. Along with these essential ingredients, some other admixtures like cereals and used products, Oil Seeds Products, Edible Starches, Milk and Milk Products, Spices and Condiments, Food Additives, etc. may be used in combination and suitable proportion for preparation of dough, as per specific requirements. Among these, the synthetic ingredients used shall be of food grade quality conforming to the requirements of PFA Act, 1954 and the rules framed thereunder. Biscuits are manufactured in varieties covering sweet, salted, filled and coated biscuits. Based on sensory attributes, the varietal differences can be easily distinguished. Based on this, biscuits have been broadly classified into the following five types: Type I - Sweet Type II - Type III - Type IV - Type V - Semi sweet Crackers Cookies Speciality Biscuits Biscuit has nowadays become a food item of mass consumption and has got wide acceptance among all the levels and class of consumers. Types of Complaints, Major Reasons of Failures Normally certain specific complaints are received by the manufacturers of biscuits from the consumers. The majority of the complaints are regarding the shape and sizes of the biscuits and taste of the biscuits.

7 Reasons for these complaints: One of the most common cases of complaints is about the irregular shape and non-uniformity in the sizes of biscuits. These problems happen primarily due to the wear and tear of the cutters on account of constant usage or due to improper alignment of the cutters. The problem with the taste can be attributed to a couple of factors like improper proportioning and compounding of the biscuit dough, inadequate or excessive baking time in the oven, comparatively low or high temperature of the oven at the time of baking, etc. Sometimes, sudden disruption in production due to power failure also causes these types of problems. These problems should normally be taken care of at the beginning of production every day by means of inprocess quality control checks. Page 4 Apart from the company standards being followed by the biscuit industry, the applicable requirements under PFA Act 1954, and the rules framed there under, other applicable statutory and regulatory requirements, some of which are mandatory and others voluntary in nature, are also followed by the manufacturers by suitably adopting them during the process of manufacture. Page 5

8 SECTION 3 SPECIFICATIONS & HYGIENE REQUIREMENTS The Indian Standard specification for biscuits i.e. IS 1011:2002 prescribes both physical as well as chemical tests: 1. Physical requirements (as per Clause 6.1) 2. Chemical requirements (as per Table 1): a) Moisture, percent by mass b) Acid Insoluble Ash (on dry basis), percent by mass c) Acidity of extracted fat (as oleic acid), percent by mass Besides the above, the standard also prescribes requirements for packaging i.e. containers and materials used for packing biscuits shall conform to the requirements specified in Clause 7.1 of IS 1011: For packets weighing 150 g and above, the standard specifies that complaint slip should be included in the containers/ printed on the labels. A detailed list of test equipments, apparatus and chemicals required to test for chemical requirements as prescribed in IS 1011:2002 is enclosed at Annex I. Note: Efforts have been made to compile the list as per the standard covering all the required test equipments, apparatus and chemicals. However, in case any omission or incorrectness is noticed while referring, the same may be conveyed to CMD immediately for suitable actions. The standard also prescribes hygienic conditions which are required to be followed by the manufacturer within their premises during mixing, processing, handling, packing and storage of finished biscuits, details of which are laid down in IS For guidance of IOs, explanatory notes have been provided against each of the requirements of respective clauses of IS 5059 in Annex II of this manual. The IOs are expected to assess the hygienic conditions being followed by a manufacturer in totality against the requirements of the standard. The standard also prescribes labeling provisions under clause 7.2. Filled or coated biscuits, which are speciality biscuits, are sandwiched with a filling of cream, which has got permitted flavours and permitted food colours among other ingredients. This is reflected in the marking clause which provides for a declaration by the manufacturers that the biscuits contain permitted colours and added flavours. Page 6 As far as possible, labeling of the product shall be done in accordance with IS 7688 Code of Practice for labeling of Pre-Packaged Foods. Biscuits are manufactured using the following raw materials in suitable combinations and proportions based on requirements. The probable sources of availability of some major raw materials are given below: Name of raw material Source of procurement Whether or not accompanied by test certificate Whether tested in-house Maida or wheat Normally procured from No; but test certificates are Yes

9 flour open market/ Flour Mill issued by the mills only on request Sugar Open Market No Yes Fat or shortening -- do -- No Yes Edible Salt -do- Conforming to IS 253 or IS Food Colour -do- With ISI Mark - MANUFACTURING PROCESS & CONTROLS Page 7 SECTION 4 IS 1011 does not prescribe any specific process for manufacturing of biscuits. However, the definitions given under the standard provide information regarding steps that may be followed in the actual practice. The process of manufacturing of biscuits is essentially a gradual baking process over a temperature gradient of raw biscuit dough prepared by mixing various raw materials in desired proportions. There are various established processes commercially available and being practiced by different manufacturers. The manufacturing of biscuits mainly involves the following process: a) Pre-mixing of raw materials b) Mixing of raw materials c) Formation of biscuit dough d) Layering of the dough e) Cutting, punching & stamping of the laminate to required shape & size f) Milk spray g) Baking h) Cooling of the baked biscuits

10 j) Packing Flow chart of Manufacturing Process: A typical Manufacturing Process Flow diagram is given in Annex III List of Machineries used in manufacturing process: Primarily the following machines are used for manufacturing processes: i. Flour Shifter ii. Stainless Steel Mixer iii. GMS Churner iv. Fat Churner v. Cotton Conveyor vi. Laminator vii. Teflon coated cutting, stamping & punching m/c. viii. Milk sprayer ix. Electrically/ Diesel operated baking oven x. Cooling conveyor xi. Pouch packing & sealing m/c. Steps involved in Biscuit Manufacturing: Page 8 A normal sequence involved in the process of manufacture of biscuits can be given as follows: i. Pre-mixing followed by mixing of the various raw materials in desired proportions for formation of the biscuit dough. ii. Formation of the dough layer of the desired thickness by placing the dough on a conveyor and passing it through a set of Teflon rollers. iii. This is followed by cutting, punching and stamping of the layer by using a set of Teflon dies of the desired shape and size. iv. After punching of the layer for formation of the biscuits, the remnants of the dough are separated out and milk spraying of the raw biscuits is done. v. Subsequently, the raw biscuits are baked through a continuous temperature gradient in a baking oven, electrically operated or diesel fired, by carrying the conveyor through the oven at a regulated speed. vi. After the biscuits come out of the oven, these are cooled to room temperature by means of a cooling conveyor vii. Once the biscuits come down to the room temperature, these are packed in polypouches of food grade quality in various pack sizes. Creams are inserted for formation of cream biscuits, wherever required, prior to packing. In-process Quality Control checks: During the process of manufacture certain quality controls checks are carried out by the manufacturers at the various stages of production. These can be briefly given as follows: i. Preparation of ingredients Correct weight of each major ingredient ii. Creaming of fat, sugar, additives and mixing of dough Homogeneity, consistency and machinability iii. Moulding and cutting Raw weight of the biscuits iv. Baking Heat Profile, Baking time v. Cooling Weight, Gauge, Colour, Flavour, Texture, Crispiness

11 vi. Packing Correct weight of packet, Moisture This apart, the conveyor speed and the temperature of the oven are also monitored closely to take care of any deviations in the process. As the product is sensitive to contamination, the entire process of manufacturing, right from pre-mixing of raw materials to the storage of packed material needs to be carried out under controlled hygienic condition. The requirements given in IS 5059, as given under Annex II, provide detailed guidelines for preventive measures to take care of all types of contaminations. Sources of contaminations may be related to equipment and pipelines used for various processes, product containers, environmental conditions, surroundings, personnel hygiene etc. Page 9 Before starting and after completion of production, all the equipment and containers need to be cleaned and disinfected so as to minimize the chances of contamination due to susceptibility of the material to these things. One of the ways to ensure sanitization of equipment and containers is to follow the cleaning chart given in Appendix A to IS Page 10

12 SECTION 5 CERTIFICATION CRITERIA Biscuits have throughout been under voluntary certification. The certification came into being against IS 1011:1957. It has since been revised thrice and the current version has been published as IS 1011:2002. For the purpose of certification of Biscuits, the operational guidelines as given under latest Operational Manual for Product Certification are to be followed. However, specific details as relevant for IS 1011 are given below: Scheme of Testing & Inspection The latest STI is Doc. STI/1011/4, April 2003.This STI is attached at Annex IV for ready reference. The other related documents such as Marking Fees, Testing Charges, List of BIS and Outside Approved Labs. for the product are available by circulation of hard copies as well posted on BIS Intranet. CHECK LIST FOR SCRUTINY OF APPLICATION & RED FORM Presently, general Check-lists are being used for scrutiny of application and Red Form. PRELIMINARY & PERIODIC INSPECTIONS USEFUL TIPS FOR IOs 1. To verify the actual factory layout. The layout should clearly indicate the different locations preferably including the following: a. Bore well or entry point for the source of water, pipeline etc. b. Raw materials storage facility c. Plant for the manufacture of the product (with various stages) d. Packing areas, change room(s), toilet(s), loading/unloading points e. Entry/exit with indications of double door/door closures/air curtains wherever provided f. Stores for packaging material and finished product g. Laboratory h. Actual boundary/perimeter of the establishment Page As product is under voluntary certification, there is every likelihood of getting stock of finished lots of biscuits during Preliminary Inspection. However, it is essential to get some production and packing done during the visit and then comment on the firm s capability for the same. 3. It should be clearly reported in the Preliminary Inspection Report as to whether the packaging adopted is manually operated or automatic. 4. Biscuit being a food item, it is essential that samples be got tested in factory for all requirements, with purpose of verifying manufacturing capability (process controls), competence of the QC personnel and working conditions of test equipment. 5. For sample drawn for independent testing, requirement of Description, Odour & Taste should be tested and reported in PIR, as these are subjective tests.

13 6. Shelf-Life ( Best Before ) Period should be clearly indicated on the test request. 7. It is important to assess the firm s installed production capacity as well as capability to store the product. Accordingly both the production capacity and storage facility need to be reported. 8. Hygienic conditions need to be assessed as per every clause of IS Declarations made by the firm with respect to medical examination, Pest control, Pollution Control Board Certificate, hygiene schedule, supervisor designated for hygiene maintenance, overall supervision, criteria devised for assessing product durability etc. be verified and reported. All aspects related to reusable containers, availability of arrangements for washing, cleaning (outer surface), disinfection and rinsing be also verified and reported. Calibration of Instruments A record for calibration of Lab. equipments should be maintained by the firm. The following instruments are considered necessary for calibration: a) Electrical Moisture Meter (To be calibrated once in a year). b) Electric Oven (To be calibrated once in a year) c) Weighing Balance (To be calibrated once in a year) d) Muffle Furnace (To be calibrated once in a year) e) Thermometer (To be calibrated once in a year) Minimum requirement of QC Staff Page 12 There should be at least two quality control personnel, for carrying out routine analysis and checks as per the requirements of Indian Standard. The QC personnel should be minimum science graduate with Chemistry background and sufficient experience/ competence to carry out the testing. Drawal of Sample(s) for Independent Testing for considering Grant of Licence i) One sample each for the different types of biscuits intended to be covered in the scope of the licence, should be drawn from the finished lot for independent testing. ii) Shelf-life Sample Sample is not to be drawn for Shelf-life assessment. iii) Selection of Laboratory for Testing Policy Guidelines circulated for the purpose of selection of Lab has to be followed. Scope for the licence to be granted for Biscuits Licence shall not be granted with open scope i.e., without specifying the type of biscuits. The grant of licence letter and the subsequent Licence Document shall clearly indicate the type of biscuits. Extension of Scope (inclusion of variety) in the licence There are many instances when licensees request for considering permitting additional types of biscuits, although basically the product may remain the same. These may be considered based on the following: a. No fresh declaration in CMD/PF 305 and PF 306 is required, since no additional testing equipment/ manufacturing m/c. is required for producing the new varieties

14 b. Associated hygienic conditions are verified c. Shelf-life is to be declared Periodic Inspection a) Frequency of periodic inspection Minimum two periodic inspections in an operative year shall be carried out. Frequency of periodic inspections should be uniformly spread throughout the period. b) Reporting on variations of results recorded by the licensee The IOs are expected to verify and report on parameters tested by the licensees. Page 13 c) Reporting on compliance to other requirements of STI It shall be verified that the formats used by the licensee are in accordance with the guidelines given in the STI. It may be possible to ascertain the quantities manufactured by the firm on Each Control Unit from the records maintained for BIS and not to rely only on the figures provided by the firm separately either from their production books or dispatch documents. d) Hygienic Conditions For assessing Hygienic Conditions, all aspects as per IS 5059 be critically assessed and reported as per the prescribed checklist. Overall assessment shall be reported as Satisfactory or Unsatisfactory keeping in view the following: i. Whether significant requirements of IS 5059 are complied ii. Whether there is critical flaw in the operation leading to contamination. e) Evidence of Testing Samples of biscuits are to be tested according to relevant IS specification during periodic inspection. f) Checkpoints to be followed by the manufacturer A manufacturer is required to check and record the values right from the raw material stage upto dispatch. A list of the parameters to be checked for the mandatory raw materials alongwith their general acceptance criteria as per normal company standards are already given in Section 1 above. This apart, there should be well defined process control points along with the process parameters being checked at the respective control points with their acceptable limits depending on the company standards. Finally, before dispatch, the manufacturer should test for all the requirements as per IS 1011:2002, on the finished lot of biscuits, as per schedule given in the STI. Biscuits belonging to a lot can be dispatched only after conformity to IS is established through tests. Guidelines w.r.t. dispatch of Biscuits by the licensee 1. Biscuits may be dispatched after ensuring conformity of a batch to all the requirements of ISS except for acid insoluble ash, which is tested on weekly basis. Page 14

15 2. As and when a failure is noticed in any of the test requirements in a batch during testing of the finished lot as per the Scheme of Testing and Inspection of BIS, the same shall not be dispatched. Also the previous batches available in stock shall not be permitted for release into the market. The manufacturer should reject all the batch held in stock and found failing. 3. Further, the manufacturer would be required to take immediate corrective action, which would involve complete investigation and analysis of the reasons for contamination and non-conformity. Only after the completion of satisfactory corrective action, the manufacturer should re-start production and only after the availability of satisfactory results of all tests as applicable for each control unit for five consecutive batches produced, stocks can be released in the market. The manufacturer will inform BIS in all such cases regarding the corrective action taken and keep complete records of the same for review by BIS. 4. The manufacturer would be required to give an undertaking to this effect to BIS. Guidelines for Stop Marking/ ROM i) Guidelines for stoppage of marking for Biscuits are enclosed in Annex V. ii) For consideration of resumption of marking, the guidelines provided in OMPC should be followed. Handling Complaints on Biscuits As the product is meant for mass consumption and also related directly to the health and safety of the consumers, it is quite likely that complaints may arise for the same. The product is not expensive and therefore as per the latest OMPC a replacement can straight away be arranged to the complainant. However, the aspect related to the following need to be addressed suitably: i) Redressal to the complainant may be arranged either from the existing stock (if declared to be conforming) or from the fresh production after resumption of marking is permitted to the licensee. ii) If it is not possible to establish the complaint by visual examination, due to the nature of complaint, it would be necessary to draw sample for independent testing. However, the material which has already been opened shall not be drawn for such purpose and an unopened, intact pack pertaining to the same lot/batch/mfg. date shall be drawn. Page 15 ANNEX I LIST OF TEST FACILITIES FOR BISCUITS AS PER IS 1011:2002 Sl. No. Tests Clause Ref. of IS 1011: Moisture 6.3 and Sl. (i) of Table 1 Refer Method of Test/ Refer to IS Ann. B of IS 1011: 2002 Test Equipment/ Apparatus Method I Moisture Meter (Electrical) Chemicals Remarks Method II

16 2 Acid Insoluble Ash 3 Acidity of Extracted Fat 6.3 and Sl. (ii) of Table and Sl. (iii) of Table 1 Ann. C of IS 1011: 2002 Ann. D of IS 1011: 2002 Moisture Dish (Porcelain/ Silica/ Glass/ Aluminium) Electric Oven Dessicator Analytical Balance Mortar & Pestle Dish (Porcelain/ Silica) Muffle Furnace Water Bath Dessicator Analytical Balance Pipette 50 ml Whatman s Filter Paper No. 42 Litmus Paper Soxhlet s Apparatus with 250 ml flat bottom flask Analytical Balance Hot Air Oven Pipette 50 ml Microburette 10 ml Thimbles Dil. HCl 5N Phenolphthale in Reagent KOH solution 0.1M Ether Ethanol (95%) Stock Solution Petroleum Ether Primary Standard (Oxalic Acid) Capable of operating ºC L.C. = 0.1 mg ºC LC= 0.1 mg Page 16 ANNEX II GUIDELINES FOR ASSESSMENT OF HYGIENIC CONDITIONS REQUIREMENT OF INDIAN STANDARD 1 SITE 1.1 A biscuit manufacturing unit shall preferably be situated in an open, clean and healthful locality 1.2 The ground of the premises surrounding the factory building should be clean and preferably paved or turfed to lay the dust. 2 BUILDING 2.1 Structure The building shall be of a permanent nature and shall be of brick and lime plaster, cement, concrete or any EXPLANATORY NOTES FOR GUIDANCE Areas in front of the main entry to the unit and immediate surroundings should be paved (pucca) or properly grassed to prevent dust contamination due to vehicular traffic Buildings should be sound pucca construction, preferably plastered and

17 other material which ensures cleanliness. 2.2 Construction of the building shall be such that it shall be rodentproof, flyproof and birdproof. The building and yard, with fittings and equipment should be kept free from breeding places of flies and other insects, by eliminating cracks and crevices, as well as by routine and thorough cleaning 2.3 Ventilation & Lighting The unit shall be adequately lighted and ventilated, keeping in mind the number of workers, their hours of work and nature of operation. Ventilation and lighting shall be also in accordance with the Factories Act, 1948, amended up to date. properly painted/ white washed. Internal partitions made of plastic may be accepted. Exhaust openings should be covered with wire mesh or with suitable flaps. IO should judge the adequacy of light intensity required for carrying out various activities. Suspended light bulbs and fixtures should be protected by providing suitable covers. Page Floor The floor shall be washable, with sufficient drainage facility, and it shall be impervious to water and not affected by weak acids, alkalies or steam. 2.5 Internal Wall The internal wall shall be smooth; it should be tiled or cement plastered or made of any other impervious material, where wash basins/sinks are installed, the walls shall be tiled or made impervious to water up to a desired height from the floor to safeguard the wall from water seepage The flooring should be smooth, without any cracks/ broken surfaces. Joints shall be properly filled and smooth. The slope of the flooring should be such as to avoid any stagnation of water. Drains should always be in clean condition and provided with traps to prevent the entries of rats/ pests. In case of cemented walls, tiles upto height of about 5 to 8 feet from floor level should be provided. Wall made of smooth plastic material may be accepted. 2.6 Ceilings The ceilings shall be kept clean Ceiling should preferably be pucca cemented and smooth. However, factories with tin/aluminum/ asbestos shed should have proper smooth false ceiling made of non absorbent material (like plastic). Wood or similar material should not be used as it may attract fungal/ mould growth. 2.7 Maintenance & Repairs The building shall be maintained in a proper state of repair and cleanliness. Whenever required, it shall be lime-washed, painted, disinfected or deodorized. There shall be no cobwebs in any part of the unit. 2.8 Preparation and filling tables shall be of wooden tops or covered with aluminium or stainless steel sheets or otherwise made impervious to water as far as There should be proper separation between different processing activities like preparation of biscuit dough, production line of biscuits, etc. Exhaust of laboratory should not open in processing/ packing/ storage areas.

18 practicable. All surfaces coming into contact with the food shall be free from pits, crevices and loose scales and shall be non-absorbent. Page All internal joinery work should be of simple design for easy cleaning and for minimizing flour dust deposit. In all rooms woodwork surrounding doors, windows and other openings should be fixed tight to the internal wall surfaces so as to avoid open joints which may harbour pests Store Rooms The store rooms for raw and packing materials should be free from dampness and should be rodentproof Wherever possible a separate room for storing machinery, equipment, spare parts, pesticides, etc. shall be provided in a location convenient to various preparation and processing areas 2.12 Proper places shall be provided for storage of brooms, brushes, buckets and other cleaning gears. 3 FACTORY & PROCESSING HYGIENE 3.1 Waste and rubbish shall be collected in covered receptacles and shall not be allowed to lie about on the floor 3.2 Adequate measures shall be taken to prevent growth of moulds on equipment and internal structures of processing and storage rooms. Adequate steps shall be taken to prevent infestation of cockroaches and other household pests. 3.3 When pesticides and/or disinfectants are used, care shall be exercised to prevent contamination of equipment, raw materials and packing materials. 3.4 Floors and drains shall be kept clean. In the processing rooms, drains shall be provided with detachable covers. 3.5 Sinks and troughs used for washing ingredients and utensils shall not be used for washing of hands. A separate room should be available for storage of raw and packing materials. This room should be separated from storage areas meant for raw materials and finished goods. Facilities for storage of waste and inedible material should be outside the processing plant and finished product storage area. Pesticides designated safe for use in food industry should only be used under direct supervision of trained personnel. Explanation same as given in cl. 2.4 Pesticides designated safe for use in food industry should only be used under direct supervision of trained personnel. Page No lavatory, sink, cesspool or garbage shall be so situated or maintained that odours or fumes therefrom pervade any room where the product or raw material are prepared or stored. 3.7 The factory effluents shall be disposed off in a hygienic manner and shall not be let off on road or adjacent fields. 3.8 Window glass and light fittings shall be generally kept clean. 3.9 Container Cleanliness It shall be ensured that the containers are clean. The containers shall not be stacked in a manner which Pipe line carrying the effluent and waste should preferably be of red in colour.

19 allows the contamination of the product Domestic animals shall not be allowed in any part of the unit. 4 INSTALLATION OF EQUIPMENT 4.1 All equipments shall be installed on a foundation of durable, easily cleanable material. 4.2 Equipment shall be placed away from the walls with a view to providing facilities for inspection and cleaning. 4.3 Installation of the pipes shall be such as to facilitate easy cleaning and maintenance. 5 EQUIPMENT AND CONTAINER CLEANLINESS 5.1 All electrical connections, such as switch boxes, control boxes, conduit cables shall be installed in such a way as to facilitate proper cleaning. 5.2 All equipment coming into contact with raw materials or the product shall be kept clean. An ample supply of water, hose, brushes, detergents and sanitizing agents and other equipment necessary for the proper cleaning of machinery and equipment shall be available. 5.3 All processing systems shall be cleaned at the close of operation or at the termination of the continuous operation period. Disinfection of process equipments should preferably be done either before commencement of production or after close of operation. Page 20 6 WATER 6.1 There shall be an adequate supply of water. The water shall be of potable quality. 6.2 The equipment shall be so installed and used that back siphonage of liquid into the potable water lines is precluded. 6.3 Hot or cold water in ample supply shall be provided for plant clean-up needs where necessary 6.4 The storage tanks for water should, unless completely sealed, be kept covered, examined regularly and cleaned out at least once every six months. 7 EMPLOYEE HYGIENE 7.1 Every person employed in the factory shall be medically examined before employment. Periodical medical examination of the employees shall be subsequently carried out to ensure that they are free from contagious, communicable diseases. It shall be impressed on all employees that they should notify the medical officer, cases of vomiting, diarrhoea, typhoid, dysentery or any other notifiable disease occurring in their own homes and families. Different colour coding should be provided so as to easily distinguish between different pipe lines. The pipe line meant for potable water should preferably be green in colour. Medical examination of all workers, testing personnel and supervisors should be got done at least once in a year or as and when required. In case of any new worker joins, his fitness with respect to freedom from communicable diseases should be first medically examined before permitting work.. Medical examination report should clearly indicate that the workers are free from any communicable diseases.

20 7.2 Employees shall keep their finger nails short and clean and wash their hands with soap or detergent before commencing work and after each absence, especially after using sanitary conveniences. Towels used for drying hands should be clean. 7.3 All employees shall be inoculated and vaccinated against the enteric groups of diseases once a year and against smallpox once in two years. In case of an epidemic all workers shall be inoculated. A record shall be kept. Page No worker shall be allowed to work without proper clothing. 7.5 Employees shall be provided with clean uniform or aprons or both and clean washable caps, where necessary. The uniforms shall not be worn outside the plant but put on just before starting the work and changed when leaving. 7.6 Eating, spitting, nose cleaning or the use of tobacco in any form or chewing betel leaves shall be prohibited within the manufacturing, packing and storage area of the unit. Notice to this effect shall be prominently displayed. 7.7 Sufficient and suitable sanitary conveniences shall be provided, maintained and kept clean in every factory. The conveniences shall be properly lighted. Separate conveniences shall be provided for each sex. No convenience shall open directly into any work room in the factory. 7.8 Sufficient wash basins with adequate provisions of soaps and towels, latrines and urinals in the prescribed manner should be provided, conveniently situated and accessible to workers at all times while they are at the factory. 8 CLEANING CHART 8.1 A routine cleaning chart should be drawn up and implemented. It may be on the lines of Appendix A to IS Page 22 ANNEX - III Entrance to the production unit should be through change room. Protective clothing, footwear and head gear should be changed inside the change room only. Change room should have hand washing facilities (with hot and cold water), wash basin, foot cleaning and drying facilities. Changing facilities like aprons, headgears, mask etc. should be available in sufficient numbers to meet daily and contingency requirement. The protective clothing should be taken out as and when workers go out of the production hall, so as to prevent any contamination of the same. Toilets should be provided for workers and should always be kept clean. Toilets should be made of pucca structured preferably tiled with proper doors and water facilities. Hand and foot washing facilities should be provided adjacent to toilets. Notices giving instructions for hand and foot washing after using toilets (in local languages) should be pasted at proper places.

21 TYPICAL PROCESS FLOW CHART RAW MATERIAL RECEIPT PRE-MIXING OPERATIONS QUALITY CONTROL RAW MATERIALS INGREDIENTS FINISHED GOODS MIXING BAKED PRODUCT LAYERING MIXER DOUGH CUTTING/ STAMPING PACKING FEEDING SHEETING COOLING BAKING OVEN STORE DESPATCH Page 23 ANNEX - IV DOC: STI/1011/4 April 2003 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF BISCUITS ACCORDING TO IS 1011:2002

22 (Fourth Revision) 1.0 LABORATORY- A laboratory shall be maintained, which shall be suitably equipped and staffed, where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 1.1 All the testing apparatus shall be periodically checked and calibrated and records of such checks/calibration maintained. 2.0 TEST RECORDS- All records of tests and inspection shall be kept in suitable forms approved by the Bureau of Indian Standards. 2.1 Copies of any records and other connected papers that may be required by Bureau shall be made available at any time on request. 3.0 QUALITY CONTROL- It is recommended that, as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397(Part 1):2003, IS 397 (Part 2):2003 and IS 397 (Part 3):2003]. 3.1 In addition, efforts should be made to gradually introduce a quality management system in accordance with the quality system modules as per IS/ISO STANDARD MARK The Standard Mark(s), as given in column (1) of the First Schedule of the licence shall be printed on the container of biscuits or on the label applied to the container, as the case may be, provided always that the material in each container to which this mark is applied conforms to every requirement of the specification. 5.0 MARKING In addition the following particulars shall be clearly & indelibly marked or labeled on each container/ packet: a) Name of the product; b) Trade Name, if any; c) Name and address of the manufacturer; Page 24 DOC: STI/1011/4 April 2003 d) Batch or Code Number; e) Net mass in grams or kilograms; f) Type of biscuits (optional); g) List of ingredients in descending order of their composition by mass; h) The statement contains permitted colours and added flavours, if added; i) Month and year of manufacture; j) Best before (month and year to be given by the manufacturer), and k) Other labeling requirements laid down under the Standards of Weights and Measures (Packaged Commodities) Rules, 1977 and PFA Rules, PACKING Biscuits shall be packed in accordance with 7.1 and of IS 1011: As far as possible labeling of the product shall be in accordance with IS 7688 Code of Practice for labeling of pre-packaged foods.

23 7.0 LEVELS OF CONTROL- The analysis and tests as indicated in Table 1 and at the levels of control specified therein, shall be carried out on the whole production of the factory and appropriate records and charts maintained in accordance with clause 2.0 above. All the production which conforms to the Indian Standard and covered under the scope of licence shall be marked with the Standard Mark. 7.1 CONTROL UNIT For the purpose of this scheme, the quantity of biscuits of the same type manufactured in a day shall constitute a control unit. 7.2 One sample of baked and finished biscuits shall be drawn from the production line in the first hour of production of each type of biscuits every day and shall be tested for moisture content (in case it is determined by using moisture meter, the moisture meter shall be calibrated periodically against the oven method). If the moisture content of the sample does not exceed 3 percent, this may not be tested for that particular type of biscuit produced continuously on that day. If it is found that the moisture content exceeds 3 percent, sample shall be drawn every four hours and tested for moisture content. In case any sample fails to meet the moisture content requirement, the material manufactured during the respective four hours of production shall be considered unfit for the purpose of marking. Page 25 DOC: STI/1011/4 April RAW MATERIAL A sample from each consignment of Edible salt, if used in the preparation of biscuits, shall be tested for conformity to IS 253 or IS 7224 and appropriate records maintained. Alternatively, a certificate giving test results for various parameters for conformity to IS 253 or IS 7224 shall be obtained from the suppliers for each consignment of Edible salt received in the factory and appropriate records maintained. 9.0 Routine analysis of each consignment of other raw materials, particularly fat or bakery shortening, sugar received in the factory shall be carried out and proper records maintained. All ingredients shall be clean, of good quality, and safe for use in food products HYGIENIC CONDITIONS - The biscuits shall be manufactured in premises maintained under hygienic conditions (see IS 5059 Code for hygienic conditions for large scale biscuits manufacturing and bakery units). A routine cleaning chart should be drawn up by the licensee and implemented as per IS All the workers engaged in production and packing shall use clean, washed clothing, including head-covers. Incidental contamination from soiled equipment or from personnel suffering from injuries, eruptions or boils shall be avoided Al the raw materials as well as the finished product shall be stored in suitable places taking care to see that adventitious impurities do not find an entrance In respect of all other clauses of the specification, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the various requirements of the specification REJECTION- A separate record providing the detailed information regarding the rejected control units and mode of their disposal shall be maintained. Such material shall in no case be stored together with that conforming to the specification.

24 13.0 SAMPLES- The licensee shall supply, free of charge, the sample (s) required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from his factory or godowns. The BIS shall pay for the samples taken by it from the open market. Page 26 DOC: STI/1011/4 April REPLACEMENT- Whenever a complaint is received soon after the goods with Standard Mark have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods are replaced free of cost by the licensee, in case the complaint is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge the conformity of the product to the Indian Standard shall be with the Bureau In the event of any damages caused by the goods bearing the standard mark, or claim being filed by the consumer against BIS Standard Mark and not conforming to the relevant Indian Standards, entire liability arising out of such non conforming products shall be of licensee and BIS shall not in any way be responsible in such cases STOP MARKING - The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of the product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to BIS. The marking of the product shall be stopped immediately if directed to do so by BIS for any reason. The marking may then be resumed only after permission is given by the BIS. The information regarding resumption of markings shall also be sent to the Bureau PRODUCTION DATA The licensee shall send to BIS, as per the enclosed proforma, a statement of the quantity produced, marked and exported by him and the trade value thereof during the half year ending 30 June and 31 December. This statement is required to be forwarded to BIS on or before the 31st day of July and January for the proceeding half-year. Page 27

25 IS 1011:2002 BISCUITS Table 1 LEVELS OF CONTROL (Para 7 of the Scheme of Testing and Inspection) DOC: STI/1011/4 April 2003 TEST DETAILS LEVELS OF CONTROL REMARKS Clause Requirement Test Method No. of Frequency Clause Reference Samples 6.1 General Requirement 6.1 Sensory In accordance with the existing practices in the factory 6.3 & Table 1 Moisture Annex B IS 1011:2002 One Every four hours Also see para do -- Acidity of Extracted Annex D -- do -- One Each Control Unit Fat -- do -- Acid Insoluble Ash Annex C -- do -- One Once a week (Each type) FORM 1 RECORDS OF TEST RESULTS FOR BISCUITS Date Type of biscuits Time at which Time at which sample Baking Texture Design Odour production started drawn (1) (2) (3) (4) (5) (6) (7) (8) Flavour Taste Insect/fungus Harmful/Injurious Moisture Acidity of Acid Quantity Remarks infestation foreign matter Extracted Fat Insoluble Ash (9) (10) (11) (12) (13) (14) (15) (16) (17)

26 ANNEX V GUIDELINES FOR STOP MARKING FOR BISCUITS I. The enclosed flow chart as given in the latest Operating Manual for Product Certification, gives the sequence of actions that will be taken by Branch Offices of BIS in the event of receiving a failing test report of biscuits or if serious deficiencies are observed during surveillance visits. II. The various procedures outlined in the flow chart provide an opportunity to the manufacturer to take corrective actions within a short time after the failure/deficiency has been observed. The procedure also provides for verification of the corrective actions by BIS shortly after receiving the intimation from the licensee. However, incase the deficiency is found to be continuing or the same is again found to be failing on re-testing, the stop marking shall be issued to the licensee which will be followed by a notice for cancellation of licence by the Deputy Director General (Region). In such an event the licence would be cancelled unless the licensee is able to provide convincing reasons on why he could not take the required corrective actions. III. Resumption of marking will be allowed after verification of the corrective actions taken by the unit and conformance of fresh samples. This will also apply in cases where DDG (R) permits continuation of licence after giving the cancellation notice. IV. In case of complaints the sample will be tested within the shortest possible period and on receipt of the test report the actions with the licensee will be taken in the same manner as per other independent test reports. Page 29 MANUAL FOR CERTIFICATION OF JUTE & JUTE PRODUCTS Draft manual for certification of UPVC pipes, MSN, 18 July

27 BUREAU OF INDIAN STANDARDS MANAK BHAVAN 9, Bahadar Shah Zafar Marg New Delhi Draft manual for certification of UPVC pipes, MSN, 18 July