B.

Sc in Food and Process Engineering

Course Code: AFE 400

Course Title: Attachment Training
Level: 4 Semester: II

Industrial Training Report at

Submitted by

Student ID Name of the Students

1707006 Md. Ikramul Habib Maruf

1707028 Jannatul Ferdous Promity
1707047 Md. Mahbubur Rahman Khan
1707059 Julkifal Islam
HAJEE MOHAMMAD DANESH SCIENCE AND TECHNOLOGY UNIVERSITY

1
Acknowledgements

Firstly, we are thanking the Almighty for providing us with the ability and chance to complete the
industrial training.

We would like to show our sincere gratitude to Dr. Md Sultan Mahmud, Professor in the
Department of Food Engineering and Technology at Hajee Mohammad Danesh Science and
Technology University, for his constant inspiration, perceptive advice, and essential direction
throughout the course of our industrial training. His guidance helps us in all the time of industrial
training and writing of this report. We could not have imagined having a better supervisor and
mentor for our study.

We are grateful to Dr. Md. Sazzat Hossain Sarker, Professor and Chairman of the Department of
Food Engineering and Technology at Hajee Mohammad Danesh Science and Technology
University for everything that he has done to manage our internship in such a renowned food
industry and all the steps he takes to advance our department and ensure its success.
We also like to extend our gratitude to Dr. Maruf Ahmed, Professor and Chairman of the
Department of Food Processing and Preservation for his ceaseless guidance and communication
with the industry authority regarding this internship.
We owe "Dhaka Ice Cream Industries Ltd." for giving us the chance to work with them as interns
in their reputable sector. We would especially want to express our gratitude to Md. Mostafa
Kamal, DGM of Production, Mr. Akter Hossain, HR, Maidul Islam, Production Manager and
Iftekhar Ahmed, Executive QA officer, Dhaka Ice Cream Industries Ltd for their kind cooperation
and ongoing supervision, which enabled us to successfully finish the industrial training. We owe
a debt of gratitude to each one of the production officers, QA officers, technicians, supervisors,
operators, helpers, and other employees who were so kind to us during the course of the
industrial training.

We would like to thank our all teachers for the continuous support of our study and for their
patience, motivation, and immense knowledge.

2
Table of Contents
Chapter 1……………………………………………………………………………………………………1
Introduction…………………………………………………….…………………………………………1
1.1 Background……………………………………......…………………………………………………………….6
1.2 Objectives……………………………….……….…………………….………………………………………….6

Chapter 2.......................................................................................................7
General Information about Dhaka Ice cream Industries Limited.....................7
2.1 Basic Information of the Organization........................................................................8
2.2 Overview of Dhaka Ice Cream Industries Ltd .............................................................9
2.3 Board of Directors.......................................................................................................9
2.4 Location and Contact Information.............................................................................10
2.5 Working Shift..............................................................................................................11
2.6 Products of Dhaka Ice Cream Industries Ltd..............................................................11
2.7 Certifications of Dhaka Ice Cream Industries Ltd.......................................................12
2.8 Distributional Channel and Promotion.......................................................................13
2.9 Goals & Principles......................................................................................................14
2.9.1 Goals..................................................................................................................14
2.9.2 Guideline Principles............................................................................................14
2.10 Food safety and quality policy....................................................................................14

Chapter 3.......................................................................................15
Production area............................................................................................15
3.1 List of Raw Materials.............................................................................................16
3.2 List of Packaging Materials....................................................................................16
3.3 Terms related to ice cream manufacturing...........................................................17
3.4 Different units of production area........................................................................18
3.5 Basic flowchart of Ice cream production..............................................................19
3.6 Details about different machines.........................................................................20
3.6.1 Machine Name: Mark Line.....................................................................20
3.6.2 Machine Name: Viking 6 cone filling......................................................22
3.6.3 Machine Name: Viking 6 cup filling.......................................................24
3.6.4 Machine Name: Rollo 23 Automatic Ice Cream Bar Freezer..................26
3.6.5 Machine Name: Rollo 20 Automatic Ice Cream Bar Freezer................28

3
Chapter 4..................................................................................30
Chapter 5..................................................................................30
Conclusion...............................................................................................31
5.1 Limitations Encountered During Industrial Training.......................................31
5.2 Conclusion.......................................................................................................31

4
Chapter 1
Introduction

5
1.1 Background
Industrial training acts as a bridge between trainees and industry to give trainees hands-on
experience. Motivate trainees to acquire practical knowledge, acquire new skills and become
experts in their fields. Industrial training minimizes the gap between theoretical and practical
knowledge. Industrial training is essential for educating qualified and successful engineers in
industrial environments. Such training has specific goals to improve competence, productivity,
and performance.
Trainees gain hands-on experience and experience real-life job profiles. It also helps trainees
develop leadership skills and teach responsibility. After training, trainees will discover their
capabilities and strengthen their confidence in an industrial environment. As a food engineering
graduate, it is very important to have industrial training knowledge to prepare us for a
professional environment. So, we started our internship at Dhaka Ice Cream Industries Ltd from
25 June to 7 July as part of our industrial training. At, the major organization of food industry in
Bangladesh.
Dhaka Ice Cream Industries Ltd is a renowned ice cream industry in Bangladesh. It is more familiar
as the name of Polar to us. This industry founded in 1987 with the goal of bringing out a smile,
making moments a little special with its innovative range of tasty and quality ice creams.
As aspiring food engineering graduates, our main direction is food production. Therefore, during
our internship, we mainly focused on the production part of the industry. In addition, we also
cover other areas of the industry. Get a complete picture of how the industry as a whole works
in the areas of supply chain management, and QC test laboratories, working principle of machine,
product mixing units and industrial engineering. To keep going, we went through almost every
department of this company, trying to find activities, plans and much more. We have deliberately
explained these things according to the situation

1.2 Objectives
The objectives of the internship were as follows:
• Learn practical knowledge and broaden our academic knowledge.
• Increased ability to apply theory to real working conditions.
• Collection of information on the manufacturing process of ice cream.
• Have a clear understanding of the production environment.
• Establish a sense of responsibility and good work habits in us as employees.

6
Chapter 2
General Information
of
Dhaka Ice Cream Industries Ltd

7
2.1 Basic Information of the Industry
Dhaka Ice Cream Industries Ltd is a leading ice cream industry with professional workmanship,
extensive marketing, reasonable discipline, and consistent efforts in Food and Beverage sector.
This company employs approximately 5000 people. It has become Bangladesh’s one of the largest
ice cream industries. During our internship period we got to know about their new plant in Savar,
Dhaka with more efficient and sophisticated machinery and latest technology to expand their
production rate and to create environment of supplying safety food to their valued customer.

Name of the Factory Dhaka Ice Cream Industries Ltd

Year of establishment 1987
Type Food and Beverage
Number of Employees 501 - 1000
Annual Turnover 199 million USD

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2.2 Overview of Dhaka Ice Cream Industries Ltd.
In very short time of 30 years, Dhaka Ice Cream Industries Ltd has grown into a renowned ice
cream industry in Bangladesh. This year Polar wore a contemporary new look and glossed up its
offerings keeping the same goal of bringing out a smile, making moments a little special with its
innovative range of tasty and quality ice creams. Most of the raw materials they import from
Australia and Europe.

Back in 1987 when Polar started, the story however was quite different-one with remarkable
farsightedness and wisdom. It all started when Mr. Amanullah Miah, a visionary businessman

decided to offer modern and good quality ice cream in a rising economy with many young
people. Undaunted by the extent of challenge, he summoned experts from Denmark to help set
up a plant capable of making international standard ice creams in his city

of choice – Dhaka.

The 3rd story is a story of pragmatism. In 2009, to further strengthen its foothold, the business
welcomed Mr. Nazim Uddin Ahmed, a successful entrepreneur as a new partner. An engineer
and a business graduate, he introduced many modern management philosophies and
embedded a thriving performance culture on the foundations of a world-class food safety
management approach. Under his stewardship, Polar became the 1st ISO 22000:2005 certified
company in dairy category in Bangladesh. That's the story of Polar today.
2.3 Board of Directors

Chairman Humayun Kabir

Vice Chairman Shaikh Salauddin

Managing Director Nazim Uddin Ahmed

Director K.M Touhiduzzaman

Mrs. Shamema Nasrin
Mrs. Nafisa Sharmin Kabir
Chief Executive officer Ashraf Mohamed

Chief Operations Officer Shah Masud

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2.4 Location and Contact Info
Dhaka Ice Cream Industries Limited
80, Shaheed Tajuddin Ahmad Sharani, Dhaka - 1208
Bangladesh
Tel: +8802 887 0851 / 53 / 54
Fax: +8802 887 0850
Email us: [email protected]
Website: https://www.polarbd.com
Facebook: https://www.facebook.com/polarbd
YouTube: https://www.youtube.com/channel/UCBkb1fj2ODy4NmlnM0uFK8A
Twitter: https://twitter.com/polarbd

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2.5 Working Shift
Working hours in the factory are divided into three shifts of 6 hours for officers related to
productions and quality control. Everyone in the production hall will be changed after 7 days.

 Shift A: 6am-2pm
 Shift B: 2pm-10pm
 Shift C: 10pm-6am
Working hours in the factory for workers, machine operators are divided into two shifts of 12
hours each. Everyone in the production hall will be changed after 7 days.

 Shift A: 8am-8pm
 Shift B: 8pm-8am

2.6 Products of Dhaka Ice Cream Industries Ltd

Category of Products Name of Products

Ice cream cake Vanilla Cake Ice Cream, Chocolate Vanilla Pound Cake,
Strawberry Vanilla Pound Cake

Cone Carnival (Vanilla), Choco delight, Carnival Strawberry, Carnival

Butterscotch

Cup Doi, Kheer, Chocolate Prime, Royal Sundae, Googly Ice Cream,
Vanilla, Strawberry, Mango, Twinee Cup (Vanilla Flavor),
Twinee Cup (Chocolate Flavor)

Litter Containers Strawberry Smile, Mango Mellow, Doi, Kheer, Zafran Malai,
Mango, Chocolate, Strawberry, Vanilla

Stick Robusto (Chocolate), Robusto (Vanilla), Crunchy, Rocks, Shor

Malai, Active Ice Lolly (Mixed Fruit Flavor), Choco Bar
(Chocolate based ice cream), Cool Shell n Core, Malai, Ice Lolly
(Orange),
2 in 1, Choco Bar (Vanilla based ice cream)

11
2.7 Certifications of Dhaka Ice Cream Industries Ltd
Organization Certificates

BSTI CM LICENSE

GAPASS CERTIFICATE

HACCAP CERTIFICATE

HALAL CERTIFICATE

ISO CERTIFICATE

12
2.8 Distribution Channel & Promotion
Distribution:
Distribution channels play a vital role in successful marking of most of the products, especially
consumer products. Dhaka Ice cream (Polar) at present has four cold stores in Dhaka,
Chittagong, Rangpur, Bogura, and Jessore, in Bangladesh.
In Dhaka city, it distributes its ice creams directly to retail stores in freezer vans. Besides that, it
has several distributors at different points of the city. Distributors cover their individual areas
where polar is not able to supply directly in its freezer vans.
For storing and selling ice creams in retail stores, company arranges a deep freezer with the
Polar logo and canopy light box (upon request from the store owner.)
In addition to this distribution, Polar also undertake home delivery of ice creams for special
occasions.

Promotion:
Promotional Activities:

 Yearly Children Competition Program

 Offering scratch cards to the consumers for discounts and gifts.
 On-line offerings:
 Polar Fan club
 Fun & games
 Cool contest
 Ecards
 Ice creams recipes
Promotional Tools:

 The essential tools for promotion of Polar Ice Cream are advertising, personal selling,
 sales promotion and direct selling. These tools are mentioned below:
 Advertisement
 Billboards
 Personal Selling
 Poster
 Publicity

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2.9 Goals and Guidelines
2.9.1 Goals: The goal of this ice cream manufacturing industry is “Polar is in the business of
making people happy with its ice creams. Every time Polar ice creams bring out a smile, making
your moments a little special, Polar gets a step closer to its goal.”

2.9.2 Guidelines
 You First
The Polar family stands strong to satisfy customers, consumers and other stakeholders
with high quality ice creams and superior services.
 Compliance and Conduct
We always comply with statutory and regulatory requirements and conduct our business
upholding ethical standards expected of a good corporate citizen.
 Innovation to Remain Preferred
We are continuously innovating products, processes and services to stay modern and
preferred.
 Accountability and responsiveness
At DIIL, we are accountable for our actions, and we respond quickly to our customers and
colleagues alike. This is our way of building a winning team.
 Wholesomeness and positive mindset
The Polar family has a healthy, sensible and positive minded approach towards everything
we do.

2.10 Food Safety and Quality Policy

Dhaka Ice Cream Industries Limited is a big family. Their motto is to uphold the superior image
of the company among its valued consumers. To maintain the highest possible consumer
satisfaction, the members of Dhaka Ice Cream Industries Limited are committed to delivering the
most hygienically produced Polar Ice Cream at affordable price.

We shall always comply with the statutory and regulatory requirements through continuous
improvements of Food Safety Management System (FSMS) and Teamwork.

14
Chapter 3
Production Area

15
3.1 List of Raw Materials
 Hot Water
 Skimmed Milk Powder
 Full Cream milk powder
 Vegetable Fat
 Sugar
 Emulsifiers
 Milk Stabilizer

3.2 List of Packaging Materials

 High density polyethylene
 Low density polyethylene
 Paper Cup
 Cartoon
 Paper Lid
 Stick

16
3.3 Terms related to ice cream manufacturing
Overrun: Overrun refers to the degree of expansion resulting from the amount of
air incorporated into the product during the freezing process. Ice cream normally
has an overrun of around 100%, meaning that air makes up 50% of its volume.
Pasteurization (CCP): Pasteurization, heat-treatment process that destroys
pathogenic microorganisms in certain foods and beverages. Temperature should
be maintained at 80 ºC to 82 ºC for 20 s to 25 s.
Homogenization: Homogenization, process of reducing a substance, such as the fat
globules in milk, to extremely small particles and distributing it uniformly
throughout a fluid, such as milk.
Aging Tank: Aging tank is the place which holds the mixture and flavors, and colors are added
here.

Chilling: Chilling is the application of cooling ice cream between the range of 0ºC to 8 ºC.
Core Temperature: Core temperature of ice cream defined as the temperature of the internal
temperature of ice cream.

Hardening Temperature: Hardening temperature means reducing the temperature of the

product up to approximately ( -26 ºC.) to obtain better consistency to make ice cream stiff enough
to hold its shape.

CIP: Clean-in-place (CIP) is a method of automated cleaning the interior surfaces of pipes,
vessels, equipment’s, filters and associated fittings, without major disassembly. CIP is commonly
used for equipment such as piping, tanks, and fillers. CIP employs turbulent flow through piping,
or spray balls for large surfaces. In their plant they used two types of CIP. Caustic CIP and Nitric
CIP. Caustic CIP is done at least once in 24 Hours. Nitric CIP is done once in week.

17
3.4 Different units of production area
Mixing Unit:
Mixing unit is one of the core units of any ice cream production plant. In mix unit raw materials
such as hot water, SMP, FCMP, Sugar, Stabilizers, emulsifiers, vegetable fats are mixed in perfect
consistency at 80 ºC to 82 ºC in a big mixing tank. After mixing all these ingredients are
transferred into Homogenizer for saturated mixing. Then the mixture goes into the chiller. Finally,
the mixture goes for the aging tank.

Production Unit:
There were two units in production area for different kinds of ice cream products. 6 types of
machines Viking 6 cup filling machine, Rollo 20, Viking 6 cone filling, Rollo23, Mark line, Rotary
Ice Cream Cup and Cone Filling Machine were arranged in fixed position attached with freezer in
two separate units. Overrun occurs in freezer. Different red colored steam lines, green colors
lines carrying ammonia gases, air lines were arranged with freezer for overrun process.

Hardening Unit:
There is a hardening tunnel through which all the cup ice creams, cone ice creams, Littre items
passes for 45 minutes at ( -28 ºC) to obtain better consistency to make ice cream stiff enough to
hold its shape.

Palate Room:
Palate room is attached with hardening unit. Before entering the storage unit all the products
wait here for 30 minutes.

Storage Unit:
Finally, all the products shifted into storage unit from palate room. Here temperature is (-40 ºC).

Quality Control Unit:

All the testes regarding to the ice cream production process are done in QC unit.

 Physical Tests: packaging materials test

 Chemical Tests: water test, fat test, chemical test for raw materials, moisture test.
 Microbiological test: Coliform test of raw materials, final products, Yeast Mold test,
Microbial load of air, detection of pathogenic microbs.

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3.5 Basic flowchart of Ice cream production

19
3.6 Details about different machines
3.6.1. Machine Name: Mark Line
Products: 2 in 1, Crunchy, Robusto, Rock,
Specification of Products:(Robusto)
 St basic weight: 48-48.7 gm
 St gross weight: 50.5-50.7gm
 Overrun:( 70-72) %
 Volume: 75 ml
 Weight of stick: 1.2 gm
 Dozing Temperature: (-5.20) ºC
 Cooling Temperature: (-40) ºC
 Temperature of cholate coating: (25) ºC
 Biscuit Coating Percentage: 8%
 Thickness of ice cream: 17mm
 Speed of Machine:73 to 74 per minute
 Core temperature: (-22) ºC
 Weight of wrapper: 1.3 gm
 Length of wrapper: 195mm
 Sealing Temperature: (155) ºC
 Cutting Temperature:(192) ºC
 Pieces per Carton: 24 pcs
 MRP:70/=

20
3.6.1.1 Mark Line Flow Chart
Aging Tank

Freezer (Gel Mark F-300)

SS cutting + Stick insertion

Hardening Tunnel (-40) ºC

Catcher

Hammering

Chocolate Coating

Ice Cream Conveyer

Packaging Line

Packaging (Sealing & Cutting)

Final Product

Palate Room

Cold Storage

21
3.6.2 Machine Name: Viking 6 cone filling
Products: Carnival (Vanilla), Choco delight, Carnival Strawberry, Carnival
Butterscotch
Specification of Product: Carnival mini cone
 St basic weight: 27.49gm
 St gross weight: 46.694gm
 Overrun:( 105) %
 Net Volume: 70 ml
 Weight of stick: 1.2 gm
 Dozing Temperature: (-5) ºC
 Dark chocolate spray temperature:61 ºC
 Dark chocolate weight: 3gm
 Nut toppings weight: 2gm
 Milk chocolate toppings: 2gm
 Hardening temperature: -26.2 ºC
 Baking temperature of biscuit:150-160 ºC for 40 to 45 min
 Weight of lid: 0.6gm
 Dozing weight:31gm
 MRP:30/=

22
3.6.2.1 Viking 6 cone filling Flow Chart
Allusive+ Biscuit in Cone Conveyer

Dozing of Dark Chocolate

Dozing of Ice Cream

White Chocolate topping

Nuts Topping

Dark Chocolate Topping

Addition of Lid

Press the Lid

Pusher

Conveyer Belt

Hardening Tunnel

Packaging

Palate Room

Cold storage

23
3.6.3 Machine Name: Viking 6 cup filling
Products: Doi, Kheer, Chocolate Prime, Royal Sundae, Googly Ice
Cream, Vanilla, Strawberry, Mango, Twinee Cup (Vanilla Flavor), Twinee
Cup (Chocolate Flavor)
Specification of Product: Kheer
 Net Volume: 110ml
 St Basic weight: 63.17gm
 St Gross weight: 75.67gm
 Over Run: 95%
 Nuts Topping: 2.5 gm
 Dozing Temperature: 5.2 ºC
 Cooling/ Hardening Temperature: (-30) ºC
 Machine Speed: 120 per mint
 Pieces per Carton: 12
 MRP: 50/=

24
3.6.3.1Viking 6 Cup Filling Flow Chart
Aging Tank

Freezer (FF-1600)

Cup in Mold
Dozer

Topping

Lid Closing

Pusher

Conveyer

Packaging

Hardening Tunnel

Palate Room

Warehouse

25
3.6.4 Machine Name: Rollo 23 Automatic Ice Cream Bar Freezer

Products: Choco Bar, Sormalai, Selenco

Specification of Product: Choco Bar
 Net Volume: 72ml
 St Basic weight: 45-46gm
 St Gross weight: 57.6-60.6gm
 Over Run: 48.76%
 Dozing Temperature: -2.4 °c
 Cold brine Temperature (-35.5°c)
 Hot brine Temperature (15°c)
 Chocolate Coating Weight: 10-12gm
 Chocolate Coating Temperature: 30°c
 Stick Weight: 1.2gm
 Stick Dimension: 114*10*2
 Packet Weight: 1gm
 Sealing Temperature: 168°c
 Cutting Temperature: 187°c
 Machine Speed: 115 per mint
 Pieces per Carton: 24
 MRP: 30/=

26
3.6.4.1 Flow Chart of Rollo 23

Aging tank

FF-800

Dozing(-2.4°c)

Cold brine(-35.5°c)

Sticking

Warm brine(14-15°c)

Catcher

Chocolate coating(10-12gm)

Packaging line (ice cream conveyer)

Packaging (cutting & sealing)

Final product

Palate room

Warehouse

27
3.6.5 Machine Name: Rollo 20 Automatic Ice Cream Bar Freezer

Products: Malai, Lolli (Orange, Lemon, Active)

Specification of Product: Malai
 Net Volume: 40ml
 St Basic weight: 43-44gm
 St Gross weight: 45.5-46.5gm
 Packaging Wrapper: 1.4 gm
 Stick: 1.2gm
 Dozing Temperature: 7-8 ºC
 Cold brine Temperature (-35.5°c)
 Hot brine Temperature (15°c)
 Length: 100mm
 Sealing Temp. of Wrapper: 190°c
 Cutting Temp. of Wrapper: 195°c
 Machine Speed: 127 per mint
 Pieces per Carton: 30
 MRP: 15/=

28
3.6.5.1 Flow Chart of Rollo 20

Aging tank

Dozing(8°c)

Cooling (Cold brine -35.5°c)

Sticking

Warm brine(14-15°c)

Catcher

Pusher

Packaging line (ice cream conveyer)

Packaging (cutting & sealing)

Final product

Palate room

Warehouse

29
Chapter 5
Conclusion

30
5.1 Limitation Encountered During Industrial Training
• The workers and engineers found it very challenging to give us enough time due to the
continuous production.
• Occasionally, a small number of employees gave us inaccurate information because they
weren't always technically correct on certain subjects. As a result, we were uncertain about
a few issues.
• Several areas prohibited taking photos.
• The machine specification label provided by the machine maker could not be found since
some of the factory's equipment was so outdated.
• Certain portions are off-limits to outside visitors. As a result, we talked to some other
people and learned a little bit about these places. Which were insufficient for our needs in
terms of data collection.

4.2 Conclusion
In Bangladesh, Dhaka Ice Cream Industries Ltd. is a well-known manufacturer of ice cream. It
became clear to us during our industrial training at Dhaka Ice Cream Industries Ltd that quality
is crucial in the food manufacturing.
We thoroughly understood management, laboratory, production, and utility services, among
other things. Aside from our four years of academics, it was a truly worthwhile opportunity for
hands-on learning. The training fills the knowledge gaps between theory and application. An
engineer will be unable to work in accordance with the skills established by his academics since
manufacturing floor workers cannot understand technical words. We picked up a variety of
organizational behaviors during this period of industrial training. We intend to use that
appropriately throughout our professional careers

31