Doritos Case Study

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Position of Maize in World Cereals 2010-11 Total cereals production in the world is 688MM ha, with a a production of 2,458 MMT annually. Below is the split of this production FAOSTAT 2012 Position of Maize in Pakistan Cereals 2010-11 In Pakistan, total area under cereals production is 13MM ha, with a production of 34 MMT annually. Below is the split of crop and its yield. FAOSTAT 2012 To process Doritos locally, a complete production line is required, starting from corn grain silo till stacking units. Total CAPEX for Doritos line $8MM CAPEX for Processing Equipments $6MM CAPEX for utilities $2MM The capacity of this line will be 5,000 Ton/ year. Doritos manufacturing has been described in detail below Doritos line Layout: List of Machines: Sr. No. Machine Application / Use 1 Mixer for Doritos chips production To properly mix raw materials and make dough 2 Screw Conveyor for Doritos chips production To convey raw materials from mixer to double screw extruder 3 Double Screw Extruder for Doritos chips production To form thin sheet of dough under controlled pressure and temperature by the extrusion process 4 Belt Conveyor for Doritos chips production To convey thin sheet from extruder to cutting machine 5 Cutting Machine for Doritos chips production To cut thin sheet of dough in required shape and size 6 Vibratory Feeder for Doritos chips production To feed Doritos chips in continuous fryer at controlled speed 7 Continuous Fryer for Doritos chips production To continuously fry Doritos chips in cooking oil under controlled temperature 8 Oil Extractor for Doritos chips production To remove extra oil from Doritos chips after frying 9 Flavoring Machine for Doritos chips production To add... ... middle of paper ... ...g prevent degradation of seasoning flavor. Seasoning Application The salt and seasonings are applied immediately after frying while the chips are still hot. The hot chips are conveyed into an inclined rotating cylinder, where a liquid seasoning mix is sprayed on them. Generally, the liquid mix consists of hot oil, salt, seasonings and flavoring to develop correct flavor profile. Cooling and packaging The tortilla chips are then cooled to ambient temperature and immediately packaged in moisture proof bags. Because fried products are very hygroscopic (they readily absorb and retain moisture), delayed packaging can cause a loss of crispness. The cooled tortilla chips, with about 1.5 percent moisture, are conveyed into a bagging machine. This machine automatically weighs and deposits them in a bag, which is then sealed. Details of packing spec is in exhibit 13.

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