A TECHNICAL REPORTON

STUDENTS INDUSTRIAL WORK EXPERIENCE SCHEME(S.I.W.E.S)

AT

SWEETCO FOODS LIMITED

NO 9, OBAFEMI AWOLOWO ROAD,

DUGBE, IBADAN, OYO STATE.

PRESENTED BY

LUKMAN FAITH DAMILARE

MATRIC NUMBER: 2018/1/00014FS

SUBMITTED TO

FOOD SCIENCE AND TECHNOLOGY DEPARTMENT,

SCHOOL OF AGRICULTURE AND AGRICULTURAL TECH.

FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA,NIGER STATE, NIGERIA.

IN PARTIAL FULFILMENT FOR THE

AWARD OF BACHELOR OF TECHNOLOGY (B. TECH) DEGREE IN FOOD SCIENCE

AND TECHNOLOGY.

JUNE,2023.

i
 CERTIFICATION

This is to certify that this report was compiled by LUKMAN FAITH DAMILARE

(2018/1/00014FS), a student of the Department of Food Science and Technology, Federal

University of Technology Minna on the completion of the Students Industrial Work Experience

Scheme (SIWES)

SIWES SUPERVISOR SIGNATURE/DATE

COORDINATOR SIGNATURE/DATE

HEAD OF DEPARTMENT SIGNATURE/DATE

DIRECTOR, [ INDUSTRIAL LIASON SIGNATURE/DATE

AND PLACEMENT UNIT]
 DEDICATION

This report is dedicated to the Almighty God for His loving care and protection throughout the

course of my industrial training.

I am also grateful to my parents Pastor and Mrs. Lukman and my siblings towards the success of

my program.
 ACKNOWLEDGEMENT

I am grateful to God for his protection and obvious guidance in my life through the duration of

my industrial training,

To my parents, Pastor and Mrs. Lukman who have supported me all this way, this report would

not have been possible without you.

This acknowledgement would be incomplete without my gratitude and appreciation to all my

supervisors in the Quality Control Department at Sweetco Foods Limited namely Mr. Rotimi

Adedokun, Mr. Kehinde Samuel, Mr. AdepitanOlusanya, Mr. Johnson, Mr. Oduwoga

Emmanuel, Mr. I. Gbenga, Mr. A. Oluwaseun, Mr. A. Oluwaseye, Mr. A. Rabiu, Mr. B. Tosin

and Mr. O. Oluwasegun, who took out time to tutor me on the various industrial aspects of

quality control and I am coming out of this industrial training a more knowledgeable and well-

rounded quality control intern.

Finally, to my fellow colleagues, A. Pamilerin, A. Taiwo, H. Halimah, I. Bukunmi, A. Munirah,

O. Khadijah, O. Richard, I. Zainab, A. Praise, A. Ayooluwa, O. Olamide, A. Olamide, B.

Debowale, M. Faith, A-A. Anjola, A. Peace, B. Fifoluwa, O. Esther, O. Funmi, A. Zainab.

You have made my stay here memorable and I’ve made lifetime friendships which I would

forever cherish and I would miss you all greatly.

Thank you for all the memories.

 ABSTRACT

At Sweetco Foods Limited, the confectionery production process involves many variables and

the quality control department is actively involved in performing various analysis and tests

before, during and after production of the candies (sweets without stick) and pops (sweets with

stick).

The objective of the Quality Control department is to ensure that there is no diversion from the

already set reference standards and this is achieved through three main methods which would be

thoroughly discussed in this report.

1. Chemical Quality Control

2. Microbiological Quality Control

3. On-line Monitoring

These methods all work hand in hand to ensure that the final product being released into the

market is of sound quality and are conducted with the aid of several equipment tailored for

specific purposes which would also be discussed in this report.

Contents

CERTIFICATION........................................................................................................................................ii
DEDICATION................................................................................................................................................iii
ACKNOWLEDGEMENT.................................................................................................................................iv
ABSTRACT....................................................................................................................................................v
LIST OF TABLES..........................................................................................................................................viii
LIST OF FIGURES..........................................................................................................................................ix
CHAPTER ONE..............................................................................................................................................1
1.0 INTRODUCTION TO SIWES...........................................................................................................1
1.1. FUNCTIONS OF THE SIWES UNIT..................................................................................................2
1.2. OBJECTIVES OF SIWES..................................................................................................................2
CHAPTER TWO.............................................................................................................................................4
2.0 HISTORY OF SWEETCO FOODS LIMITED.......................................................................................4
2.1 Various Departments in Sweetco Foods Limited.........................................................................4
 Security department....................................................................................................................4
 Administrative department.........................................................................................................5
 Marketing department................................................................................................................5
 Laboratory section.......................................................................................................................5
 Mechanical section......................................................................................................................5
 Power section..............................................................................................................................5
 Electric section.............................................................................................................................5
2.2 Products of Sweetco Foods and their NAFDAC numbers.............................................................6
2.3 PERSONAL PROTECTIVE EQUIPMENT (PPE).................................................................................7
CHAPTER THREE..........................................................................................................................................9
THE CANDY PRODUCTION PROCESS........................................................................................................9
3.1 RAW MATERIALS......................................................................................................................9
3.2 THE PRODUCTION PROCESS.......................................................................................................18
3.3 PACKAGING...........................................................................................................................22
3.4 REWORK.................................................................................................................................24
CHAPTER FOUR..........................................................................................................................................26
4.0 QUALITY CONTROL..............................................................................................................................26
4.1 Online quality control................................................................................................................26
4.2 Chemical quality control...........................................................................................................27
4.2.1 WATER HARDNESS TEST.....................................................................................................27
4.2.2 MOISTURE CONTENT OF RAW MATERIALS........................................................................28
4.2.3 MOISTURE CONTENT (MC) OF CANDY...............................................................................30
4.2.4 DETERMINATION OF CANDY’S pHs....................................................................................31
4.2.7 FREE FATTY ACID (FFA) TEST..............................................................................................32
4.2.8 EDTA SOLUTION PREPARATION.........................................................................................33
4.2.9 NH3-NH4Cl BUFFER PREPARATION......................................................................................33
4.2.10 ERIOCHROME BLACK T INDICATOR PREPARATION............................................................34
4.2.11 PHENOLPHTHALEIN INDICATOR PREPARATION.................................................................34
4.2.14 DETERMINATION OF TOTAL DISSOLVED SOLIDS (TDS).......................................................35
4.2.15 DETERMINATION OF TOTAL SUSPENDED SOLIDS IN WATER.............................................36
4.2.16 DETERMINATION OF ASH CONTENT:.................................................................................36
4.2.18 REDUCING SUGAR TEST.....................................................................................................37
4.2.19 ALKALINITY TEST ON WATER..............................................................................................38
4.2.20 CHLORIDE TEST FOR WATER..............................................................................................40
4.3 MICROBIOLOGICAL QUALITY CONTROL........................................................................................40
4.4 EFFLUENT TREATMENT ANALYSIS..............................................................................................44
4.4.1 EFFLUENT TREATMENT PROCESS.......................................................................................44
ANALYSIS CARRIED OUT ON EFFLUENT TREATMENT WATER............................................................46
CHAPTER FIVE............................................................................................................................................48
CONCLUSION AND RECOMMENDATION...............................................................................................48
5.1 CONCLUSION.........................................................................................................................48
5.2 RECOMMENDATION..............................................................................................................48
REFERENCES..............................................................................................................................................49
 LIST OF TABLES

Products of Sweetco foods and their NAFDAC numbers..............................................................6

 LIST OF FIGURES

Figure 1: ORGANOGRAM OF SWEETCO FOODS LIMITED...................................................7

Figure 2: AN IMAGE OF THE SUGAR COLLECTOR................................................................9

Figure 3: AN IMAGE OF LACTIC ACID AND SODIUM LACTATE......................................10

Figure 4: AN IMAGE OF THE BOILER......................................................................................12

Figure 5: FLOW CHART SHOWING THE PROCESS OF WATER TREATMENT................13

Figure 6: AN IMAGE OF THE VEGETABLE OIL BEING USED............................................15

Figure 7: AN IMAGE OF STRAWBERRY FLAVOUR AND TITANIUM DIOXIDE COLOUR

.......................................................................................................................................................16

Figure 8: AN IMAGE OF ICE MINT CANDY ON THE CONVEYOR BELT..........................19

Figure 9: FLOW CHART FOR PRODUCTION PROCESS........................................................20

Figure 10: IMAGE SHOWING PRIMARY PACKAGING.........................................................22

Figure 11: IMAGE SHOWING SECONDARY PACKAGING...................................................23

Figure 12: AN IMAGE OF THE REAGENTS USED FOR WATER HARDNESS....................27

Figure 13: DIAGRAM SHOWING AN OVEN............................................................................29

Figure 14: SETUP SHOWING MOISTURE CONTENT ANALYZER......................................30

Figure 15: IMAGE SHOWING pH METER................................................................................31

Figure 16: IMAGE SHOWING TOTAL SOLID ANALYSIS.....................................................34

Figure 17: DIAGRAM SHOWING FURNACE...........................................................................36

Figure 18: FLOW CHART SHOWING THE EFFLUENT TREATMENT WATER..................46

 CHAPTER ONE

1.0 INTRODUCTION TO SIWES

The Student Industrial Work Experience Scheme (SIWES) was established by the Industrial

Training Fund in 1974 and it began with 748 students from 11 higher institutions. In 1978, the

scheme had been expanded to accommodate 5,000 students from 32 institutions.

The Student Industrial Work Experience Scheme is a skill training program which aims to

expose students to industrial working conditions related to their course of study and bridge the

ever-increasing gap between theory taught in schools and practical applications available in real

life working conditions. To cement its importance, the SIWES forms a part of the approved

minimum academic standard in the various degree programs for all Nigerian tertiary institutions.

The scheme is a tripartite program involving the universities, the students and the organization of

attachment and is funded by the Federal Government of Nigeria (FGN) and jointly coordinated

by the Industrial Training Fund (ITF) and the National Universities commission (NUC).

Participation in SIWES has become a necessary pre-condition for the award of diploma and

degree certificates in specific disciplines in most institutions of higher learning in the country, in

accordance with the education policy. The student industrial training work experience scheme

(SIWES) is undergone by students in either 300 level (for a 4-year course of study) or 400 level

(for a 5-year course of study) to enhance students’ capacity in relevant industries related to their

discipline. (O.A.T., 1991).

1.1. FUNCTIONS OF THE SIWES UNIT

The SIWES unit is tasked with several responsibilities to ensure that the scheme runs as

smoothly as possible and some of these responsibilities include

 Supervision of the students placed in industries located within the unit’s zone.

 Processing of students’ logbooks, ITF forms and industrial attachment reports and

students’ allowances.

 Fostering of close links between the universities and industries participating in SIWES

program.

 Provision of advisory guidance to participating students on career employment

opportunities.

 Monitoring of compliance with the requirements of SIWES on the part of students as a

condition for graduation.

1.2. OBJECTIVES OF SIWES.

The student industrial work experience scheme (SIWES) designed to fulfill the following

objectives:

 Acquaint the students with industrial practices which may likely not be available in their

tertiary institutions to prepare them for the real-life work situation after graduation from

school.

 Make the transition from the university to the world of work easier while increasingthe

chances for future job opportunities.

 Expose the student to new innovations and ideal sin their various disciplines to keep pace

with new technology innovation and discoveries.

 Provide students with an opportunity to apply their theoretical knowledge in real work

situation, thereby bridging the gap between university work and actual practices.

 Enlist and strengthen employer involvement in the entire educational process of

preparing university graduates for employment in industry (Fund, 2004).

 Provide an enabling environment where students can develop personal attributes such as

critical thinking, creativity, initiative, resourcefulness, leadership, time management, and

interpersonal skills.
 CHAPTER TWO

2.0 HISTORY OF SWEETCO FOODS LIMITED

Sweetco Foods Limited are a part of the ZARD group of companies based in Ibadan, Oyo

state of Nigeria. The ZARD group have diversified into various business industries including

manufacturing, distribution, construction, packaging, farming, livestock, furniture and

education.

Sweetco Foods Limited are manufacturers of candies and with over 10 products, they hold a

large share in Nigeria’s candy market. It was founded in 1999 on about 10 acres of land with

2 production plants and just 2 products but within a space of 10 years, 4 more production

plants were added alongside 8 other different products showing the dedication to growth and

willingness to expand their market share.

All products are approved by the National Agency for Food and Drug Administration and

Control (NAFDAC) as the company ensures strict compliance with regulatory standards

while constantly improving product quality and meeting up with the booming market

demand.

2.1 Various Departments in Sweetco Foods Limited

 Security department: At the moment, the security company “Halogen” is contracted

to oversee the safety of Sweetco Foods Limited and this department is in charge of

ensuring the company premises are adequately secured while every visitor is

thoroughly vetted to know the purpose of visit before being allowed entry into the

premises. There are regular stop and search operations at various checkpoints within

the compound to prevent theft of materials and equipment.

 Administrative department: They are concerned with the day-to-day running of the

company and take care of all administrative functions.

 Marketing department: They are in charge of the buying and selling of the products

such as candies and confectionary after production, which includes the sales (income

and outcome exchange) of aggregates and selling of materials in the company.

 Laboratory section: This section includes quality assurance, analysis and control

activities on both the raw materials used in the factory and their finished product on a

daily basis. This is always carried out under a controlled environment to improve the

standards of the company.

 Mechanical section: This section helps in the maintenance of all the machines and

tools used in all aspect of production. It also includes the welder’s workshop.

 Power section: It consists of the boiler system and the generator system. The boiler

systems generate steam (in form of heat) to the machine in the factory while the

generator system provides power to the factory when the power source goes out

 Electric section: The candy processing machine control panels seem to come from

the electrical section. Almost all machines are powered in the control room, a room

filled with different electrical components and a computer system which powers

every other machine.

 Packaging section: This section controls the packaging of the candy and pop been

produced, which include the primary packaging, secondary packaging and tertiary

packaging for better storage, sales and consumer satisfaction.

 Cleaning section: This section comprises the cleaners who are in charge of cleaning

the machines, floors, walls of the factory and toilets.

2.2 Products of Sweetco Foods and their NAFDAC numbers.

Table 1: Products of Sweetco Foods and their NAFDAC numbers

S/N PRODUCT NAFDAC NIS NUMBER

NUMBER

1. MILKOSE 01-3680 FT-709

2. KONACAFE 01-5164 FT-708

3. STRAWBERRY 01-6662 FT-707

SPLASH

4. ICE-MINT 01-6661 FT-705

5. BANANA POP 01-1153 NIL

6. STRAWBERRY POP A1-1155 NIL

7. ORANGE POP A1-1162 NIL

8. MELODY CANDY 08-1767 NIL

9. MANG-OH 08-1765 NIL

10. POPY LOLLIPOP 08-1763 NIL

ORANGE

11. TAMARIN 08-5783 NIL

12. TROPIC COCONUT 08-5781 NIL

POP
2.3 PERSONAL PROTECTIVE EQUIPMENT (PPE)

Every staff of Sweetco Foods Limited undergoes a safety induction after which the appropriate

personal protective equipment has to be worn before heading to the designated workplace. This

is done to protect the individual from injury when working in a particular area or on a particular

piece of equipment. Some personal protective equipment include:

a) Reflective jacket

b) Safety boots

c) Helmet

d) Hair cover and overalls

e) Ear plugs and hand gloves.

MANAGING DIRECTOR
 GENERAL MANAGER

COMMERCIAL FINANCE
ADMINISTRATIVE
MANAGER

MAINTENANCE PROCUREMENT
QUALITY PRODUCTION
MANAGER
CONTROL MANAGERM
SECTIONAL
MARKETING ACCOUNTANT
PERSONNEL
MARKETING SHIFT MANAGER
SHIFT
CASHIERS
MICROBIOLOGY SALE OFFICER

PROCUREMENT
SUPERINTENDENTS
EXECUTIVE
OFFICER SECRETARY
CLERKS

TECHNICIANS

SUPERVISORS
PHYSIOCHEMICAL

TRAINERS

Here is an Organogram of Sweetco Foods Limited. (Figure 1.)

 CHAPTER THREE

THE CANDY PRODUCTION PROCESS

3.1 RAW MATERIALS.

1. Sugar

2. Glucose syrup

3. Lactic acid and Sodium lactate

4. Water.

5. Condensed Milk.

6. Brine.

7. Lecithin.

8. Vegetable oil.

9. Flavours.

10. Colour.

3.1.1 Sugar

Sugar is the generalized name for sweet, soluble carbohydrates, they are mainly made up

of carbon, hydrogen and oxygen and can be derived from various sources. Some examples of

sugar include glucose, fructose, and sucrose. Chemically different substances may also have a
sweet taste, but are not classified as sugar. Some are used as lower-calorie food substitutes for

sugar and are referred to as artificial sweeteners(Jackson, 1995).

Figure 2: An image of the sugar collector

3.1.2 Glucose syrup.

Glucose syrup is food syrup, made from hydrolysis of starch. Maize is commonly used as

the source of the starch in the US, in which case the syrup is called corn syrup. Glucose syrup is

also made from other starch crops including potatoes, wheat, barley, rice and cassava through

either acid hydrolysis, enzyme hydrolysis, or a combination of the two and contains over 90%
glucose used in industrial fermentation while syrup used in confectionary manufacture contain

varying amounts of glucose, maltose and higher oligosaccharides, depending on the grade and

can typically contain 10% to 43% glucose. Glucose syrup is used in foods to soften texture, add

volume, prevent crystallization of sugar, and enhances flavor.(Hull, 2010).

3.1.3 Lactic acid and Sodium lactate.

Sodium lactate is a salt of lactic acid which has a mild saline taste andis produced by

fermentation of sugar sources such as corn or sugar beets. This fermentation is done by

neutralizing the lactic acid to create sodium lactate(NaC3H5O3).

The sodium lactate used in candy production as a food additive with number E325 and is mostly

in liquid form but it can also be found in powdered form. It acts as a preservative in the candy

and also serves as an acid regulator.

3.1.4 Water

Water is a universal solvent and dispersing agent as well as a very reactive chemical

compound. At room temperature, water has the highest specific heat of an inorganic or organic

compound with sole exception of ammonia.

The water used in Sweetco Foods Limited comes from the borehole and goes through some

series of water treatment in the boiler room before being passed into the production line. The raw

water from the borehole is collected to the raw water tank which then passes to the sand filter

tank. The sand filter tank contains meshes that are of various sizes which remove the sand, stone

and all particles including both sinking and floating present.

From the sand filter, the water then goes to the activated carbon filter which deodorizes and

decolorize the water after which the water moves to the ion exchange resin tank where ions like

sodium, calcium, manganese and iron are trapped and removed. This removal is done to prevent

the ions forming scales at the bottom of the tank.

The water continues its movement from the resin tank to the reverse osmosis tank which

possesses a pressure membrane that removes further impurities, then it goes further through the

heat exchanger tank where it is partially heated and briefly diverts to the condensate where it is

fully heated before reaching the feed water tank which serves as a conduit for the water into the

boiler.

The boiler which could either be 8-ton or 4-ton is a chamber that takes the water through several

relevant processes. The boiler contains a tube through which heat is transferred into the water

and after this tube is heated by a burner, it heats the water in return. On boiling, the steam

produced which is about 10 bar passes through pipes and is directed into the production plants.
When the steam cools, it is referred to as condensate and moves to the condensate tank. Each

production plant has a condensate pump linked to the condensate tank.

Figure 4: AN IMAGE OF THE BOILER

 Raw water (borehole)

Sand filter tank

Activated carbon tank

Ion exchange resin vessel

Reverse osmosis

Process water tank Feed water tank

Production Plant Boiler water tank

Blow down water

Steam

Condensate

Figure 5: FLOW CHART SHOWING THE PROCESS OF WATER TREATMENT

3.1.5 Lecithin:

Lecithin is an oil-like extract from soybeans used to preserve, emulsify and moisturize foods.

Many candy companies use lecithin as an emulsifier in real chocolates, caramel and taffy

because it is cheaper than cocoa butter and less is needed for similar results. Usage

recommendation is 0.25-0.50% lecithin per total batch as too much lecithin can have adverse

effects.
3.1.6 Condensed Milk:

Condensed milk is cow’s milk from which water has been removed. It is very thick and can last

for years without refrigeration if unopened. The cooking process is done between 116 0c to 1430c

to eliminate any form of microorganism such as bacteria and fungi, which grow more on milk

processed candies especially milkose.

3.1.7 Brine.

This is the mixture of salt and water and it ranges between 3.5% (a typical concentration of

seawater, or the lower end of solution used for bringing foods) to about 26% (atypical saturated

solution, depending on temperature). Other levels of concentration are called different names

based on dissolved salt such as fresh water, saline water.

3.1.8 Vegetable oil.

Vegetable oil is a triglyceride extracted from plants. The term vegetable oil can be defined as

plant oils that are liquid at room temperature. Vegetable oil is used in candy production to

improve its aesthetic appearance and to aid easy removal from the mold on cooling by reducing

stickiness of other ingredients while also improving the flavor qualities of candy. They also carry

flavours of other ingredients since many flavours present in chemicals are soluble in oils.
Figure 6: An image of the vegetable oil being used

3.1.9 Colours and flavours.

Flavours and colours are responsible for the difference in candies as they give unique

properties. All the colours are first dissolved in water before being added and they are always in

the ratio of 1kg of the colour powder to 10kg of water.

Regarding the flavour, each product has a distinct flavour. For example:

1. Ice mint: Minty flavour and brilliant blue colour is used

 2. Milkose: European fragrance flavour is used.

3. Strawberry splash/strawberry pop: Strawberry flavour and cream, titanium dioxide

[white colour] and Allura red are used

4. Banana pop: Banana and cream flavour, tartrazine yellow and titanium dioxide colour is

used.

5. Melody/watermelon candy: Water melon flavour and pea green colour is used.

6. Mang-OH: Mango flavour is used.

7. Knock-out candy: Coconut flavour and cream are used.

Figure 7: An image of strawberry flavour and titanium dioxide colour

3.2 THE PRODUCTION PROCESS.

 Auto feed tank: This is an automated machine where all the raw materials are introduced

and homogenized in measured quantity for each batch process. The raw materials could

include sugar, glucose syrup, brine, vegetable oil.

 Reservoir tank: This serves as a mixer, where all the recipes are being collected at a

certain amount for a batch (a batch lasts for about 9 minutes.)

 Heat Exchanger: This contains the dissolver and the pre-cooker where the candy is

slightly cooked.

 Pre-cooker: This is a first stage of cooking. The cooking temperature is between 121 0c to

1290c. This cooking helps to kill microorganisms present and prevent solidification of the

syrup. There is a coil inside the pre-cooker which helps the syrup to move down to the

flash vessel. The temperature of the pre-cooker depends on the candies produced.

 Flash vessel: Forproducts that require milk, it is introduced at this stage to prevent

denaturation of the milk during the cooking of the syrup. The milk calibration depends on

the number of strokes been run during production. Rework is also introduced at this stage

in the flash vessel at a specific speed.

 The micro-film/ cooker: This is the final stage of cooking and condensation of the vapors

into liquid also occurs at a temperature of 145 0c. The microfilm consists of blades that

rotate clock wisely and anti-clock wisely. The blade aids complete homogenization of the

syrup. The temperature also depends on the candies being produced.

 The collection chamber: For product that required acid, acid is introduced here. There is a

discharge pump under this chamber which pumps the syrup up to the incorporator
 The incorporator: This stage is where the difference in the candies is finalized as the

colour and flavour are introduced here. The colour and flavour goes into the syrup at a

calibrated speed and the number of stroke speed that is been run at that point.

 The hopper: The hopper consists of three main components namely the nozzle, piston and

the manifold. They all work closely to allow the injectors/pistons inject the syrup into the

mold which gives the candy its desired stage. The speed at which the hopper runs is

known as the stroke and the calibration of acid, flavour and colour depends on the stroke

being run.

 The cooling tunnel: From the hopper, the mold moves to the cooling tunnel which

consists of large air conditioners that help to cool the candies at 30 0c. This cooling

process is necessary to aid the removal of candy from the mold and also to prevent

candies from melting in their wrappers, after which the candies are conveyed to a larger

conveyor belt which then diverts them to individual wrapping machines.

 Packaging: Candies undergo three different packaging; we have primary packaging,

secondary and tertiary packaging

Figure 8: AN IMAGE OF ICE MINT CANDY ON THE CONVEYOR BELT
 RAW MATERIALS

AUTOFEED

RESERVOIR

PRE-COOKER

FLASH VESSEL

MICROFILM

INCORPORATOR TANK

HOPPER

MOLDS

COOLING TUNNEL

WRAPPING
MACHINES

PACKAGING

Figure 9: FLOW CHART FOR PRODUCTION PROCESS

3.3 PACKAGING.

A pouch of candy contains 48 to 52 pieces of candy and weighs between 184 and 192g and there

are 20 pouches placed in cartons. The packaging material (poly propylene and Bi-Axially

oriented polypropylene (BOPP) used is sourced locally from NISALEE and POLYFILM which

are both packaging materials producing companies. All products are packaged according to

hygienic standards. There are 3 stages of packaging involved in candy production and they are:

 Primary packaging

 Secondary packaging and

 Tertiary packaging

3.3.1 PRIMARY PACKAGING

This is the immediate wrapper of the candy. It is the package in direct contact with the naked

candy. For normal candies, the weight of a wrapped candy is between 3.60 – 3.73g and only a

single candy should be inside one wrapper while for pops, the average weight of a stickpop

should be between 6.8 – 7.2g.

The gram square meter test is carried out on the wrapping film and it includes cutting off a piece

of film, measuring the length and breadth and eventually calculating the gram square meter. This

test is performed to ensure that the packaging material meets the required standards.
Figure 10: IMAGE SHOWING PRIMARY PACKAGING

3.3.2 SECONDARY PACKAGING

This is the second stage of wrapping and the candies are packaged in pouches by the bagger.

Each pouch contains between 49 and 51 pieces with the average weight of each pouch ranging

between 184-192g while each pouch of pop weighs between 410-420g/pouch.

Figure 11: IMAGE SHOWING SECONDARY PACKAGING

3.3.3 TERTIARY PACKAGING

This is the final packaging stage where the pouches are packaged into cartons (10 pouches per

carton for pops and 20 pouches per carton for candies). The average weight of each carton of

candy is about 4kg. The cartons are then arranged on wooden pallets (48 for pops and 72 for

candies) and moved to the store.

3.4 REWORK

Rework is the recycling of defective candies or unused candy waste. The candies are melted in

hot water inside the rework tank and the volume of water used is determined by the number of
candies to be reworked and for effective processing, sodium bicarbonate (Na 2CO3) is also added

to the hot water.

This is necessary because it helps to dissolve impurities present in the re-work candies, acts as

preservative and also neutralizes the candy pH. It is necessary to neutralize the pH because

candies are already acidic in nature as acid was added to them in the course of production, and

since the rework is going to be added back into freshly prepared syrup to which acid would still

be added, a neutral pH is required to prevent hyper-acidity.

 CHAPTER FOUR

4.0 QUALITY CONTROL

Quality control is the process of ensuring that products meet already specified standards and

requirements. It is carried out with the use of systematic activities that take place during the

production process to evaluate, measure and control the quality of the final product.

Though similar to quality assurance, there is a difference as quality assurance involves the use of

statistical analysis and covers a wider scope from the reception of raw materials till the product

gets to the final consumer while quality control only covers the production process and it would

not be erroneous to state that quality control is a subset of quality assurance.

At Sweetco Foods Limited, the production process is automated and monitored with the

necessary equipment at regular intervals to ensure compliance to set criteria and if to minimize

defective candy products.

The quality control department in Sweetco Foods Limited is divided into four sections:

 Online quality control

 Chemical quality control

 Microbiological quality control

 Effluent treatment analysis

4.1 Online quality control

The online quality control analysis is predominantly done on the production line and it involves

constant assessment of the candy weight, colour, taste and aesthetic appearance. The candies are
produced in a controlled atmosphere with dehumidifiers being used to prevent the entry of

moisture into the hygroscopic candy. During online quality control analysis, there are hourly

checks of the candy and pop weight, wrapped candy weight, bagger weight, temperature,

humidity, wrapping machine efficiency, candy defects determination and the bagger machine

efficiency.

As at this moment, the standard weight of the wrapped candy is 3.5g while that of the wrapped

candy is 7.2g. The pouch weight which contains 50 pieces of candy or pop is 188g and 420g

respectively.

4.2 Chemical quality control.

The chemical quality control analysis is the use of classical or gravimetric methods to carry

out tests which ensure compliance to required standards. These tests include but are not limited

to moisture content of the finished product and the raw materials used, water analysis, free fatty

acid tests. (Sweetco Foods L.T.D., 1999).

In the subsequent subheadings, we discuss some of the various physicochemical tests being

carried out in Sweetco Foods Limited.

4.2.1 WATER HARDNESS TEST

Water is an essential ingredient in candy making and it is important to constantly check the level

of water hardness in each available water sample.

Below are the procedural steps for analyzing the hardness of water:

(i) Measure 50ml of water sample into a conical flask

 (ii) Add 6mL of NH3-NH4Cl buffer solution

(iii) Add 2-3 drops of EriochromeBlack T indicator

(iv) Titrate the solution against EDTA solution (inside the burette)

(v) Evaluate the titre value

Titrevaluex 1000
Calculation: = Vol. ofsample ( 50 ml )
¿
¿

This test is performed to measure and subsequently control water hardness as it is essential to

prevent sealing and clogging in water pipes.

Figure 12: AN IMAGE OF THE REAGENTS USED FOR WATER HARDNESS

4.2.2 MOISTURE CONTENT OF RAWMATERIALS

Moisture contents of raw materials are determined so as to know the amount of water to

determine the water activity. Moisture content of raw materials is important to consider because

it affects the physical and chemical aspect of food which relates to the freshness and stability for

storage

Below are the procedural steps for the moisture content of raw materials determination:

(i) Weigh an empty pan (W1)

(ii) Weigh 5g of the raw material sample into the pan (W2= weight of pan + weight

of sugar)

(iii) Spread the raw material evenly (to increase the surface area)

(iv) Put the pan containing the raw material sample into an oven

(v) Oven-dry for 4hrs at 110OC

(vi) Remove the sample from the oven and cool in a desiccator

(vii) Reweigh the raw material-containing pan after heating (W3)

(viii) Evaluate the % Moisture Content

Calculation:

W 2−W 3
% MOISTURE CONTENT= X 100
OriginalWeightof raw material (5 g)

This value is the same as

(a) % Loss on drying

 (b) % matter volatile at 105 OC.

Figure 13: IMAGE SHOWING AN OVEN

4.2.3 MOISTURE CONTENT (MC) OF CANDY

The hard-boiled candies produced atSweetco are hygroscopic and can melt when exposed to high

relative humidity. This is why it is necessary to know each candy’s moisture content to be able to

predict and extend its shelf life.

Below are the procedural steps for the determination of moisture content

(i) Take a candy sample

(ii) Grind with pestle and mortar until a fine, homogenized powder is attained

(iii) Put a measured amount (2/3g) of the powdered sample into the moisture content

analyzer for ongoing analysis or if the sample would not be analyzed

 immediately, put in a beaker and place in a desiccator to prevent the sample

absorbing extra moisture from the environment.

(iv) The moisture content analyzer would perform the analysis for 8 minutes at 105C,

after which the result would be generated automatically.

Figure 14: SETUP SHOWING MOISTURE CONTENT ANALYZER

4.2.4 DETERMINATION OF CANDY’S pHs

(i) Grind the candy with pestle and mortar

(ii) Weigh 5g of the powdered sample and dissolve in 45g distilled water

(iii) Mix thoroughly to acquire homogeneity

(iv) Determine the pH using pH meter

 Figure 15: IMAGE SHOWING pH METER

A pH > 8.4 in water may pose serious health problems like eye and mucous irritation. pH < 6.8

contribute to the corrosion of plumbing materials and release of metals such as lead, scandium,

zinc, copper into the water.

4.2.7 FREE FATTY ACID (FFA) TEST

Aim: To determine the free fatty acid present in either a vegetable oil or a fat sample to ascertain

if the raw material can be approved for production use.

(i) Weigh 5g of vegetable oil in a conical flask. (If a fat sample, it should be melted

into liquid form first.)

(ii) Add 25ml of ethanol and 25ml of diethyl ether

(iii) Add 1/2ml of phenolphthalein indicator to the solution

(iv) Titrate against 0.1M NaOH in the burette

 (v) Note when the color changes to pink

(vi) Record the titre value and calculate the FFA

Calculation:

TitreValuex 4
FFA CONTENT = (in mgNaOH/goil)
5

N.B: Standard value = ≤1.0mgNaOH/g

4.2.8 EDTA SOLUTION PREPARATION

EDTA (Ethylenediaminetetraaceticacid) solution is the titrant solution put in a burette when

testing for hardness of water. It is prepared following the process below

(i) Weigh 0.95g of EDTA (Ethylenediaminetetraacetic acid salt)

(ii) Make up to the 250mL mark in a conical flask

(iii) Store in a reagent bottle

4.2.9 NH3-NH4Cl BUFFER PREPARATION

This solution regulates the water sample pH while performing the water hardness test. It is

advisable to put on the fume chamber to avoid inhaling the pungent smell of the ammonia

solution.

(i) Weigh 17.5g of Ammonium salt into a 250mL conical flask

(ii) Dissolve the salt in 142mL Ammonium solution

(iii) Then make up to the 250mL mark of the conical flask with distilled water

(iv) Store in a reagent bottle.

4.2.10 ERIOCHROME BLACK T INDICATOR PREPARATION

This indicator is utilized also in the water hardness test and it turns the sample colour to purple

after 2 drops are added. Here’s how it is prepared.

(i) Weigh 0.2g of powdered Eriochrome Black T Reagent

(ii) Add 15mL of Tetraethanolamine

(iii) Add 5mL of ethanol(absolute)

(iv) Homogenize the solution and store

4.2.11 PHENOLPHTHALEIN INDICATOR PREPARATION

This indicator is used mainly in the alkalinity and free fatty acid test.

(i) Dissolve 0.2g of Phenolphthalein in 70mL ethanol(absolute)

(ii) Add 100mL of distilled water

(iii) Homogenize the solution and then store.

4.2.13 DETERMINATION OF TOTAL SOLIDS (TS)

Total solid is the amount of solute that can be found in our water sample (raw or process water

specifically). It is the addition of total suspended solid (TSS) and total dissolved solid (TDS). A

high total solid analysis indicates the presence of contaminants in the water sample which could

affect product quality if not properly treated.

PROCEDURE

(i) Clean the crucible and dry in the oven at 105 OC

(ii) Place it in a desiccator and allow it to cool to constant weight (W1)

(iii) Transfer 50ml of sample into the pre-weighed crucible

 (iv) Evaporate to dryness on a hotplate

(v) Cool in a desiccator and weigh (W2)

Calculation:

W 2−W 1
TS= X 1000(In mg/L)
Vol. ofsample

Figure 16: IMAGE SHOWING TOTAL SOLIDSANALYSIS

4.2.14 DETERMINATION OF TOTAL DISSOLVED SOLIDS (TDS)

Dissolved solids give taste to water at high concentration and the use of water with high

dissolved solids in industries leads to scaling in boilers, corrosion and degraded quality of the

products.

Calculation:

TDS = TS – TSS
4.2.15 DETERMINATION OF TOTAL SUSPENDED SOLIDS IN WATER

(i) Dry a Whatman Filter paper in the oven at 110OC for 1hr

(ii) Cool in a desiccator and weigh (W1)

(iii) Filter 50ml of the sample using appropriately fixed filter paper with the funnel.

(iv) After the completion of the process, ensuring the filter paper is completely

strained, carefully remove the filter paper from the funnel without tearing it

(v) Dry the filter paper in an oven at 110OC for 2hrs

(vi) Cool in a desiccator and weigh (W2)

(vii) Calculate for Total Suspended Solids (TSS)

Calculation:

W 2−W 1
TSS= X 1000(In mg/L)
Vol. ofsample

4.2.16 DETERMINATION OF ASH CONTENT:

The ash of a food sample is the inorganic residue remaining after ignition. The ash obtained is

not necessarily of the same composition as the mineral matter present in the original food as

there may be losses due to volatilization or some interaction between constituents. The ash figure

can be regarded as a general measure of quality and a high ash figure suggests the presence of an

inorganic adulterant. This is why it is a useful criterion in identifying the authenticity of a food.

PROCEDURE:

(i) Clean, dry, ignite, cool (in a desiccator) and weigh the crucible (W1).

(ii) Weigh accurately and directly in the crucible about 5-10g of solid or 25ml-50ml of

liquid sample (W2).

(iii) Ash in a muffle furnace maintained at 500-550OC until fully ash (2 hours).
 (iv) Cool the dish with ash in a desiccator and weight (W3)

Calculation:

W 3−W 1
% Ash = X 100
W 2−W 1

Figure 17: A FURNACE

4.2.18 REDUCING SUGAR TEST

α-D-glucose which contains a hemiacetal group and, therefore reacts with water to give an open-

open form containing an aldehyde group. Benedict’s reagent and Fehling’s solutions are used to

test for the presence of a reducing sugar. The reducing sugar reduces copper (II) ions in these test

solutions to copper (I), which then forms a brick red copper (I) oxide precipitate.

PROCEDURE

I. Prepare Fehling’s solution A and B depending on the difference in candies.

 II. Weigh 1g of the sample and dilute with 100ml of the round bottom flask.

III. Setup the retort stand and the burette fixed with the heating mantle

IV. Pour the candy solution in the burette and extract 15ml into a conical flask.

V. Switch on the heating mantle and put the conical flask on it

VI. Pour 10ml of Fehling’s solution

VII. Leave for 2minutes till there is a slight color change

VIII. Put 2 drops of methylene blue and titrate

IX. Note the color change and record.

4.2.19 ALKALINITY TEST ON WATER

Alkalinity is the quantitative capacity of a water sample to neutralize an acid to a set pH. This

measurement is very important in determining the corrosive characteristics of water due

primarily to hydroxide, carbonate and bicarbonates ions, anions that can be hydrolyzed such as

phosphates, silicates, borates, fluoride and salts of some organic acids. Alkalinity is critical in the

treatment of drinking water, wastewater, boiler and cooling systems and soils.

Alkalinity can be measured either as Phenolphthalein Alkalinity and Total Alkalinity. The

phenolphthalein Alkalinity is determined by neutralizing the water sample to a pH of 8.3 using a

dilute hydrochloric acid solution and a phenolphthalein indicator. This process converts

hydroxide ions to water and carbonate ions to bicarbonate ions.

−¿+HCl ⟶ H 2 O ¿
OH

−¿ ¿
−¿+ Cl ¿

CO 32−¿+ HCl ⟶ H CO 3 ¿
Since bicarbonates ions can be converted to carbonic acid with additional hydrochloric acid, the

phenolphthalein alkalinity measures total hydroxide ions, but only half of the bicarbonate

contribution. To completely convert the carbonate ions, hydrochloric acid is added until the

sample’s pH is 4.5

−¿¿
−¿+ HCl ⟶ H2 CO 3+Cl ¿
H CO3

This is known as Total Alkalinity.

PROCEDURE A (PHENOLPHTALEIN)

i. Measure 20ml sample of the water to be analyzed

ii. Add 1ml of phenolphthalein, the sample becomes pink

iii. Using hydrogen tetraoxosulphate VI, titrate till the sample color turns colorless(Sweetco

Foods L.T.D., 1999).

Calculation:

TOTAL ALKALINITY=Titre value X 250 (The result should be between 600-800ppm)

PROCEDURE B (METHYL ORANGE)

i. Measure 20ml sample of the water to be analyzed

ii. Add 2 drops of methyl orange indicator, the sample becomes yellow

iii. Using hydrogen tetraoxosulphate VI, titrate till the sample colour changes from yellow to

slight pink.
Calculation: METHYL ORANGE =Titre value X 250 (The result should be between 800-

1200ppm)

4.2.20 CHLORIDE TEST FOR WATER

Chloride ions are one of the major inorganic anions in water and wastewater. Although high

concentrations of chloride in water are not known to be toxic to humans, the regulation of its

concentration is mainly due to taste. It is essential to monitor chloride concentration in boiler

systems to prevent damage of metal parts. In high levels, chloride can corrode stainless steel and

be toxic to plant life(Sweetco Foods L.T.D., 1999).

i. Measure 50ml of sample into a conical flask

ii. Add 1ml of K2Cr2O7 [potassium dichromate] into the measured sample

iii. Fill the burette with 0.1M Silver Nitrate (AgNO3)

iv. Start the titration and note the end point (i.e., color changes from YELLOW to BRICK

RED)

Calculation:

titre value ×35.45 ×1000 × N

Chloride∈ H 2 O= in mg/L
Vol . of sample

(N = Normality of AgNO3 = 0.0282)

4.3 MICROBIOLOGICAL QUALITY CONTROL.

Microbiological quality control involves analyzing the production process for the presence

microorganisms which could possibly interfere negatively with the strict compliance standards
set already. It involves analysis of the water sample, milk samples, conveyor belts, and several

candy samples.

For the purpose of microbiological quality control, we use 5 main culture medium namely Eosin

Methylene Blue agar (EMB), Salmonella-Shigella agar (SS), Plate Count Agar (PCA), Yeast

Extract Agar (YEA), MacConkey agar (MCA). These agars are prepared according to the

manufacturer’s instruction and bearing in mind the quantity of water needed to prepare our

medium in the right mix.

 ENVIRONMENTAL MONITORING

This analysis is performed at the beginning of a production week, the production plants are all

fumigated, washed and thoroughly cleansed and the essence of environmental monitoring is to

ensure that the fumigation was effective.

PROCEDURE:

1. Weigh the required amount of each agar according to manufacturer’s instruction into a

conical flask.

2. Add distilled water and swirl to allow the powder to dissolve totally.

3. Cover the conical flask with cotton wool wrapped in foil paper

4. Sterilize all the conical flasks and petri dishes to be used.

5. After sterilization, allow to cool down

6. Pour each agar into the labelled petri dish for each production plant and allow to solidify.

7. Transfer the labelled petri dishes to the corresponding plants and expose the culture

medium to the atmosphere for at least 45 minutes.

 8. Collect all petri dishes and incubate at 37C.

 FINISHED PRODUCT ANALYSIS

This analysis is performed to determine the presence or absence of microorganisms in the

finished products.

PROCEDURE:

1. Weigh 0.4g of peptone powder for 40ml of distilled water (40ml because 4 plants are

running.)

2. Sterilize the peptone water and other sampling bottles.

3. Inoculate 9ml of peptone water into 4 sampling bottles.

4. Pulverize the candy, grind and add 1g into each of the 4 sampling bottles and allow to

dissolve.

5. 1ml is inoculated into 4 different plates, add the already prepared agar and allow to

solidify.

 MILK SAMPLE ANALYSIS

The milk analysis is done to check for the presence of Salmonella spp and other possible

microorganisms which might contaminate the milk sample.

PROCEDURE:

1. The milk sample is collected using a sampling bottle and 1ml is drawn out with a syringe

and transferred into a first micro tubule already containing 9ml of distilled water.
 2. 1ml of the sample is taken from the first micro tubule using both the syringe and needle

into the second one, covered and shaken for proper mixing.

3. Then another 1ml of the milk sample is taken from the second micro tubule into the third

one.

4. 5ml of the sample is then drawn from the third micro tubule and 1ml each is poured into

the 5 petri dishes already containing the respective agars.

5. The plates are swirled and allowed to gel after which they are incubated.

GRAM STAINING

Gram staining is a staining process used for the identification of microorganisms, it separates

microorganisms into being either gram positive or gram negative.

PROCEDURE

1. The incubated plates are brought out with visible growth on them.

2. The Bunsen burner is lit and the inoculating loop should be flamed after which it is

dipped in distilled water and transferred to a grease free glass slide.

3. The inoculating loop is used to scoop a part of the already grown microorganism and

used to make a smear on the glass slide.

4. Pass the glass slide over the Bunsen burner for the smear to be heat fixed.

5. Crystal violet is applied over the smear for 1 minute after which it is washed off with

running water.

6. Iodine is then applied for the next 45 seconds, then washed off as well.

7. Ethanol is applied next for 5 seconds to decolorize the smear

 8. Finally, safranin is applied for a minute then washed away once the time elapses.

9. The slide is placed nearby to dry, then observed under a microscope.

10. If colour pink, the organism is gram negative.

11. If colour purple, it is gram positive.

4.4 EFFLUENT TREATMENT ANALYSIS

Effluent treatment refers to the recycling of waste water before it is discarded and the objective

of effluent treatment is to release waste free water to the surrounding environment. The

wastewater generated at Sweetco Foods Ltd is channeled to the effluent treatment plant.

4.4.1 EFFLUENT TREATMENT PROCESS

The wastewater comes from the plant and passes through pipes to the collection tank which is

where diffused aeration takes place, that is, oxygen is applied from underneath the water.

The water from the collection tank is irregular in concentration and this can affect the treatment

of the water if not homogenized. To prevent this, the equalization tank has a compressor

responsible for the diffused aeration at the bottom of the waste water.

At this stage the effluent water is being treated extensively with different chemicals to stabilize

the water, control the pH and to coagulate the dirt. Some of these chemicals used in the treatment

of the effluent water include;

a. Alum: Alum acts as a coagulant and ensures the coming together of substances to form

flocs. 25kg of alum is dissolved in 500liter of water then stored in the tank with value for

control of flow rate during treatment.

 b. Hydrated lime – This is also known as calcium hydroxide (Ca (OH) 2) and its role is to

control the pH. Though naturallylime pH isbetween 8-9 but by adding it to water the pH

is between 3.5 to 6. Hydrated lime also helps soften the water for coagulation to occur.

c. Poly electrolytes: These polymers are useful in flocculation of substances in the water.

Effluent treatment can further be classified into two stages namely

 Primary stage

 Secondary stage.

THE PRIMARY STAGE INCLUDES:

 Dissolved air floatation tank (DAF) – this tank contains four chambers; the first two

chambers help in the coagulation of the dirt in the water while the other two chambers

ensure floatation. The water moves in a zigzag pattern for affection penetration due to a

longer retention time rather than a straight-line movement that may prevent effective

treatment. As water moves towards the end of the tank, there is less agitation to prevent

splitting of the coagulant

 Primary clarifier tank – this is also known as the primary sedimentation tank where

sediments are removed. The water from the dissolved air floatation tank moves freely

into this tank and the sediments settle gradually at the bottom of the tank. After

sedimentation, the water moves along to the aeration tank for the secondary stage of

treatment.
THE SECONDARY STAGE

This stage involves color and odour removal, filtration, regulation of the biochemical oxygen

demand and chemical oxygen demand and finally disinfection. The secondary stage includes the

aeration tank, secondary clarifier tank, filter tank, multigrade sand filter tank and activated

carbon filter tank.

 Aeration tank: Mechanical aeration occurs at this stage as oxygen is applied on top of the

water. The oxygen is applied to enable bioreaction and allow bacteria present in the water

to utilize the oxygen for growth as they consume the organic matter present in the water.

 Secondary clarifier: The clarifier has an activated sludge to supply bacteria.

 Filtertank: Chlorine is added in this stage to disinfect the water and kill any bacteria

which might be present in the water.

 Multigrade sand filter tank: This filter tank contains sand and stones of different sizes for

the purpose of thorough filtration.

 Activated carbon filter: Charcoal is utilized in this tank which removes any colour

present in the treated water.

 Cintropur: This is the final treatment stage and dirt is totally filtered out after which the

water is safe for release into the surroundings.

ANALYSIS CARRIED OUT ON EFFLUENT TREATMENT WATER.

There are several parameters which we analyze when treating water and some of them include

1. Appearance

2. colour

3. Odour

4. pH
5. Fat and grease

6. Total solids

7. Total suspended solid

8. Total hardness

9. Chloride

COLLECTION TANK

EQUALIZATION TANK

DISSOLVED AIR FLOATATION TANK

PRIMARY CLARIFIER TANK

AERATION TANK

SECONDARY CLARIFIER TANK

FILTER TANK

MULTIGRADE SAND FILTER

ACTIVATED CARBON FILTER

CINTROPUR

Figure18: FLOW CHART SHOWING THE EFFLUENT TREATMENT WATER.

 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

The program helps me to blend theoretical knowledge acquired in school with practical hand on

application of knowledge required to perform work in industry.

The program has also enabled me to gain experience in handling equipment and machinery

which can be found in an industrial environment.

5.2 RECOMMENDATION

Students should be properly oriented about the industrial training program and how they

can secure a placement and how to go about the filling and submission of industrial training

related forms.

Students should also see the industrial training period as a great opportunity to learn and

acquire knowledge which is why students should make wise use of this opportunity.

REFERENCES
Fund, I. T. (2004). Information and Guideline for Student Industrial Work Experience Scheme.

Industrial Training Fund ( Revised 2004), Industrial Training Fund, Jos, Nigeria.

Hull, P. (2010). Glucose syrup: Technology and Application. Wiley-Blackwell .

Jackson, E. (1995). Sugar Confectionery Manufacture. Spriger, Berlin , 132.

O.A.T., M. (1991). Students Idustrial Work Experience Scheme (SIWES) .

Sweetco Foods L.T.D. (1999). Effectiveness of HACCP in Production Company. Ibadan, Oyo,

Nigeria: Sweetco Foods L.T.D.