BUREAU OF INDIAN STANDARD (Central Marks Department-1)

Our Ref: CMD-I/3:10 12 12 2006 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.

Annexure-1 DRAFT SECTORAL MANUALS

Sl. No.

Name Scope of Awarded work

Co-coordinator details

Remarks

1. Shri S.K. Dasgupta Flat 1 E, Sheetal Chaya Apartment VIP Road, P.O. Ashwani Nagar Baguiati Kolkata 700059 Phone:033-25708644

Biscuits (IS 1011) 1 MANUAL

Shri S.K. Chaudhuri, Scientist E, MDK-3, Kolkata Phone: 033-23379474

Draft Manual received (1)

2. Shri Nilmoni Mitra 403 Udaigiri Apartment Kaushambi Housing Project Ghaziabad 201010 Ph: 0120-2775765

Rolled Steel Products (Sheets) (IS 277, , 513, 648, 1029, 1079, 1993, 2002, , 10748) 1 MANUAL

Shri B.K.Shreevastava, Scientist E, GZBO, Ghaziabad Ph: 0120-28611740

Draft Manual received (1)

3. Shri U.N. Putatunda 804 Kanchanjunga Kaushambi Ghaziabad 201010 Ph: 0120-2950637 Mob: 98186-16219

Steel Pipes, Tubes and Fittings (IS 1161, 1239(Pt. 1&2), 1978, 3589, 3601, 4270, 4923, 5504, 6392 and 9295) 1 MANUAL

Shri C.K. Veda, D&H (MED), BIS HQ Ph:011-23232509

Draft Manual received (1)

4. Shri P.Rabindranathan, Kumaramangalath House Panangad,Kodungallore Thrissur,Kerela-680665 Mob. 09447031857 Ph:0480-2851857

Natural Rubber and Natural Rubber Latex ( IS 4588 and 5430) 1 MANUAL

Shri U.K. Anabrasu, D&H, TBO, Thiruvananthapuram Ph:0471-2322104

Draft Manual Received(1)

5.

Shri M.S. Nagaraj D-201, 2nd 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)

Hebbal, Bangalore – 560024 Ph: 080 23624017 Mob:098455-59892

HDPE Pipes (IS 4984, 14333) Polythene Pipes and fittings (IS 12786, 13487, 13488, 14151) 3 MANUALS

Ph:080-28392296

6. Shri R.K. Monga B3/85-B, Lawrence Road,Delhi 110 035 Email:rajmonga@hotmail.com Mob:98689-18004 Ph: 011-27106048

Electric iron &Electric radiators + Electric Immersion water heaters and Geysers (FOR PERFORMANCE AND SAFETY REQUIREMENTS) 2 MANUALS

Sh. Ghanshyam Jha, Director MDD-2 BIS, New Delhi Ph:011-23232922

Draft Manual received for Electric Radiator (1 out of 4 identified products).

7. Shri M.A.U. Khan ,

122, Sidhartha Enclave, Ashram, New Delh-110014 Ph: 011-26345115

LPG Burning Appliances (IS 4246, 4760 and 11480) 1 MANUAL

Sh. S.D. Dayanand, MDD-1 BIS New Delhi Ph:011-23237401

Draft Manual Received (1)

8. Shri R.K. Dua Ex. DDG, BIS Flat No. 22 A, Pocket BW, DDG SFS Flats, Shalimar Bagh Delhi-110 088. Ph: 011-27473092

Jute & Jute Products (IS 1943, 2566, 2818 (Part 2), 3984, 7406 (Part 2), 12650, 15138) 1 MANUAL

Sh. P. Bhatnagar Director TXD BIS New Delhi Ph:011-23231282

Draft Manual Received(1)

9. Shri N.S. Vijayaraghavan, Saroj, Ist Floor, 5,7th Cross, Krishnappa Block, Ganga Nagar Extn. Bangalore-560 032. Ph:080-65976061 Mob: 098444-02299 Email:yenesvee2000@yahoo.com

Wire Ropes 1 MANUAL

Sh Prasada Reddy Sc ‘E’ BNBO Bangalore Ph:080-28398860 Mob: 094480-46446

Draft Manual Received(1).

For BIS Use Only Doc No.:

Date of Issue:

MANUAL

FOR

BISCUITS

(First Issue)

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9, BAHADUR SHAH ZAFAR MARG,

NEW DELHI - 110002

CONTENTS

SECTION No. PAGE No. TITLE PAGE 1 INDEX PAGE 2

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 1011. 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 1957. Since then the standard has undergone 3 revisions and the current version has been implemented with effect from 15 June 2003. 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.

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 - Semi – sweet Type III - Crackers Type IV - Cookies Type V - 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.

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 in-process 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

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: 2002. 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 5059. 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

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 7224 - Food Colour -do- With ISI Mark -

Page 7

SECTION 4

MANUFACTURING PROCESS & CONTROLS 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

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.

Page 8 Steps involved in Biscuit Manufacturing: 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

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 5059.

Page 10

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 11 2. 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.

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 5059. 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)

Page 12 Minimum requirement of QC Staff 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

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

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: 2002

Refer Method of Test/ Refer to

IS

Test Equipment/ Apparatus

Chemicals Remarks

1 Moisture 6.3 and Sl. (i) of

Table 1

Ann. B of IS 1011:

2002

Method I Moisture Meter (Electrical) Method II

• Moisture Dish (Porcelain/ Silica/ Glass/ Aluminium)

• Electric Oven • Dessicator • Analytical Balance • Mortar & Pestle

Capable of operating 105 +1ºC L.C. = 0.1 mg

2 Acid Insoluble

Ash

6.3 and Sl. (ii) of

Table 1

Ann. C of IS 1011:

2002

• Dish (Porcelain/ Silica)

• Muffle Furnace • Water Bath • Dessicator • Analytical Balance • Pipette – 50 ml • Whatman’s Filter

Paper No. 42 • Litmus Paper

• Dil. HCl – 5N 600 +20ºC LC= 0.1 mg

3 Acidity of Extracted

Fat

6.3 and Sl. (iii) of Table 1

Ann. D of IS 1011:

2002

• Soxhlet’s Apparatus with 250 ml flat bottom flask

• Analytical Balance • Hot Air Oven • Pipette – 50 ml • Microburette – 10

ml • Thimbles

• Phenolphthalein Reagent

• KOH solution – 0.1M

• Ether – Ethanol (95%) Stock Solution

• Petroleum Ether

• Primary Standard (Oxalic Acid)

Page 16 ANNEX – II

GUIDELINES FOR ASSESSMENT OF HYGIENIC CONDITIONS

REQUIREMENT OF INDIAN STANDARD EXPLANATORY NOTES FOR GUIDANCE

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.

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

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

Buildings should be sound pucca construction, preferably plastered and

other material which ensures cleanliness. properly painted/ white washed. Internal partitions made of plastic may be accepted.

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.

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 17 2.4 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.

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.

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

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.

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.

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

practicable. All surfaces coming into contact with the food shall be free from pits, crevices and loose scales and shall be non-absorbent.

Page 18 2.9 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.

2.10 Store Rooms The store rooms for raw and packing materials

should be free from dampness and should be rodentproof.

A separate room should be available for storage of raw and packing materials.

2.11 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

This room should be separated from storage areas meant for raw materials and finished goods.

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

Facilities for storage of waste and inedible material should be outside the processing plant and finished product storage area.

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.

Pesticides designated safe for use in food industry should only be used under direct supervision of trained personnel.

3.4 Floors and drains shall be kept clean. In the processing rooms, drains shall be provided with detachable covers.

Explanation same as given in cl. 2.4

3.5 Sinks and troughs used for washing ingredients and utensils shall not be used for washing of hands.

Pesticides designated safe for use in food industry should only be used under direct supervision of trained personnel.

Page 19

3.6 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.

Pipe line carrying the effluent and waste should preferably be of red in colour.

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

allows the contamination of the product. 3.10 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.

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.

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.

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.

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 21

7.4 No worker shall be allowed to work without proper

clothing. 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.

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.

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.

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.

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.

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.

Notices giving instructions for hand and foot washing after using toilets (in local languages) should be pasted at proper places.

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 5059.

Page 22 ANNEX - III

TYPICAL PROCESS FLOW CHART

RAW MATERIAL RECEIPT

PRE-MIXING OPERATIONS

QUALITY CONTROL

FINISHED GOODS RAW MATERIALS INGREDIENTS

MIXING BAKED PRODUCT

LAYERING

MIXER DOUGH

CUTTING/ STAMPING

FEEDING SHEETING BAKING COOLING PACKING 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

(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 9001. 4.0 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, 1955 6.0 PACKING – Biscuits shall be packed in accordance with 7.1 and 7.1.1 of IS 1011: 2002. 6.1 As far as possible labeling of the product shall be in accordance with IS 7688 – Code of Practice

for labeling of pre-packaged foods.

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 2003

8.0 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.

10.0 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 5059. 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.

10.1 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. 11.0 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. 12.0 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.

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 2003

14.0 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.

14.1 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.

15.0 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.

16.0 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

DOC: STI/1011/4 April 2003

IS 1011:2002 BISCUITS

Table 1 LEVELS OF CONTROL (Para 7 of the Scheme of Testing and Inspection)

TEST DETAILS

LEVELS OF CONTROL

Test Method Clause Requirement Clause Reference

No. of Samples

Frequency

REMARKS

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 7.2

-- do -- Acidity of Extracted Fat

Annex D -- do -- One Each Control Unit

-- 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 production started

Time at which sample drawn

Baking Texture Design Odour

(1) (2) (3) (4) (5) (6) (7) (8)

Flavour Taste Insect/fungus

infestation Harmful/Injurious

foreign matter Moisture Acidity of

Extracted Fat Acid

Insoluble Ash Quantity Remarks

(9) (10) (11) (12) (13) (14) (15) (16) (17)

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 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 2006 27

BUREAU OF INDIAN STANDARDS MANAK BHAVAN

9, Bahadar Shah Zafar Marg New Delhi-110002.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 28

CONTENT S SECTION NO. TITLE PAGE No. ANNEXURE

I PRODUCT DESCRIPTION 3 I, II

II SPECIFICATION 4 III, IV

III MANUFACTURING 5

PROCESS & CONTROLS

IV-1 INSPECTION & TESTING 6 V, VI

IV-2 TEST METHODS 6 VII

IV-3 TEST EQUIPMENT 8 VIII

V CERTIFICATION CRITERIA 8

VI MARKING FEE & 11

TESTING CHARGES

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 29

0. FORWARD

01. Jute is agricultural based natural fibre.This lingnocellulosic fibre is produced mainly in the eastern part

of our country. Besides India, it is produced and exported by other countries like Bangladesh, China,

Thailand, and Nepal.

The jute is biodegradable, heterogeneous in nature and hygroscopic. Being an agricultural based

product it has immense importance in the national economy. Raw jute is evaluated based on length of fibre,

color and moisture content.

0.2 This manual is prepared based on the version mentioned against relevant Indian standards along

with amendments as shown there in.

0.3 Every attempt has been made to provide salient features and necessary guidance required for

certification of jute products. While using this manual, the subsequent changes in the Indian Standard

Specifications and/ or directives issued by the Competent Authority from time to time, if any, may be

incorporated.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 30

SECTION I SCOPE AND PRODUCT DESCRIPTION 1.1 This manual is intended to serve as a comprehensive reference document for BIS certification of the jute products. It provides guidance for various technical and operational requirements prescribed in respective Indian standards and Certification Manual. This manual is intended to serve as a guidance document for internal use of BIS only. This is not to be considered as a replacement of Indian standard specification and / or Scheme of testing and inspection. 1.2 Product Description The jute products are generally classified in the following categories: Jute Yarn - Jute fibre is spun into yarn which is used for manufacture of fabric as warp and weft. Fabric- Three types of fabric namely hessian, tarpaulin and sacking are commonly used. Sacking is heavy jute fabric manufactured by using coarse jute fibre in larger percentage than used in the manufacture of tarpaulin and hessian or such light fabric in plain or twill weave. Jute Bags - Bags used for packing of food grains, sugar, fertilizers etc. are made of hessian, sacking or tarpaulin. 1.3 Specifications The specifications for the products covered in this manual are as under: Product Indian Standard A- Twill jute bags IS 1943: 1995 with Amendments Nos 1, 2, 3, &4 B- Twill jute bags IS 2566: 1993 with Amendment Nos. 1, 2, &3 Indian Hession IS 2818: 1971 with Amendment Nos 1, 2, 3, &4 DW Flour bags IS 3984:2002 with Amendment No1, Jute bags for packing fertilizers Part1 Laminated bags manufactured from IS 7406 (Part 1):1984 with Amendment No.1 407g/m2, 85x39 tarpaulin fabric Part 2 Laminated jute bags manufactured from IS 7406 (Part 2): 1986, 380 g/m2, 68x39 tarpaulin fabric Jute bags for packing 50 kg food grains IS 12650:2002 with Amendment Nos.1, & 2 Jute bags for packing 50 kg sugar IS 15138:2002 with Amendment Nos.1 1.4 Principal Requirements Principal requirements of various jute products covered in this manual are given in Annex detailed below: Product Annex Ref. A-Twill jute bags, 1A B- Twill jute bags, 1B Indian hessian, 1C DW- flour bags, 1D Laminated jute bags for packing fertilizers, 1E Jute bags for packing 50 kg food grains, and 1F Jute bags for packing 50 kg sugar. 1G 1.5 Terms and Definitions For the purpose of this manual, definitions of terms as given in IS 5476: 1986 Glossary of terms relating to textiles shall apply. Definitions of commonly used terms are given in Annex II. 1.6 Intended Usage hessian and sacking - hessian is used as packing material. Sacking is used for making bags used for packing food grains, sugar, flour etc. 1.7 Industrial/ Business Aspect

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 31

hessian and sacking are produced in jute mills. Jute bags are also manufactured by jute mills. However, sometimes jute bags are also produced / fabricated by small scale manufactures who procure sacking cloth from the mills. 1.8 Consumer Categories Fabric - Exporters and traders of jute goods. Bags - Food Corporation of India, State Govts. Sugar mills and Fertilizer manufacturers. 1.9 Types of Complaints In general there are negligible complaints about fabric. In case of jute bags, complaints in respect of dimensions, mass, breaking load, stitches /dm are received. 1.10 Major Reasons for Product Failure Jute fibre being hygroscopic and heterogeneous in nature results in variation beyond the specified tolerances. In addition jute manufacture being labour intensive (mostly unskilled) also contributes to variation in quality. 1.11 Statutory Authorities 1.11.1 The jute industry comes under the Ministry of Textiles. Jute Commissioner in consultation with the Ministry, formulates and implements various guidelines. 1.11.2 Food Corporation of India and some of the state governments e.g. Punjab, Haryana, U.P, M.P. procure jute bags as per IS 2566 and IS 12650 in bulk quantity for packing of food grains. ISI marked jute bags are pre-inspected by DGS & D at manufacture’s premises.

SECTION II SPECIFICATIONS 2.1 The specification for the items covered in this manual are given in 1.3. For manufacture of bags, the specification of fabric to be used along with Indian Standard, if any , is included in the principal requirements of various types of bags given in Annex - I . 2.2 For manufacture of jute fabric following raw materials is required

Raw material Source Specification

Raw jute Jute corporation of India IS 271 is used

Raw Jute Traders, for grading

Jute Batching Oil Indian Oil Corporation

Emulsifier Local Mkt. 2.3 References The following Indian Standards are neccessary adjuncts to this mannual. IS No. Title IS 702 1961 Specification for Industrial Bitumen IS 1954 : 1990 Methods of determination of length and width of fabrics (Second revision)

IS 1963: 1981 Methods for determination of threads per unit length in woven fabrics (Second revision)

IS 1969: 1985 Methods for determination of breaking load and elongation of woven Fabrics (second revision)

IS 2508: 1984 Specification for low density polyethylene film IS 2818(Part1): 1971 Indian hessian - Specification, Part 1 General IS 2873: 1991 Textiles - Packaging of jute products in bales - Specifications (First revision) IS 2969: 1974 Method for determination of oil content of jute yarn and fabrics (First revision) IS 3667: 1993 Textiles - B- Twill jute cloth- Specification IS 3966: 1967 DW-Flour jute cloth IS 4744: 1968 Specification for packaging of jute products in rolls.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 32

IS 5476: 1986 Glossary of terms relating to jute (first revision) IS 7407(Part2): 1980 Specification for jute tarpaulin fabric, Part 2, 407 g/m2, 85x39 (First revision) IS 7407 (Part3):1980 Specification for jute tarpaulin fabric, Part 3, 380 g/m2, 68x39 (First revision) IS 8477: 1977 Method for determination of bitumen content in laminated jute bags IS 9030: 1979 Method for determination of seam strength of jute fabrics including their laminates IS 9113; 1993 Textiles - Jute sacking -General requirements(first revision) IS 10146:1982 Specification for polyethylene for its safe use in contact with food stuff, pharmaceuticals and drinking water. IS 10889: 1984 Specification for high density polyethylene film

SECTION III MANUFCTURE & CONTROLS 3.1 Manufacturing process flow chart along with the controls to be exercised at various stages of manufacture is given in Annex III. 3.2 Hygienic Conditions Hygienic conditions are not applicable.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 33

3.3 Manufacturing Machinery The details of manufacturing machinery of a typical jute mill are given in Annex IV.

SECTION IV Part 1 - Inspection & Testing 4.1.1 Raw material (as per company standards) a) Jute i) Moisture regain ii) Tenacity Note: Generally tenacity is tested for higher grades of raw jute like TD2,TD3,TD4,BTB,BTC,BTD & visual checking is done for lower grades like TD5 & below and lower quality of Mesta. b) Jute Batching Oil i) Specific Gravity ii) Flash Point c) Emulsifier Emulsion stability test 4.1.2 in-Process Inspection The extent of in-process control exercised depends largely on end product e.g. different controls are exercised for yarn when yarn itself is a finished product as compared to yarn used for hessian and sacking due to economic considerations of the end product. The details of in-process controls exercised are given in Annex V. 4.1.3 Final Inspection The finished products are tested by licensees as per details given in respective scheme of testing and inspection. Part 2 -Test Methods 4.2.1 Mass of Bales Determine the total gross mass (Mg) of the bales under test by adding the gross mass of each bale corrected to the nearest kilogram. Remove the baling hoops and all other packing materials of the bales and weigh them together up to the nearest kilogram. Calculate the total tare mass (Mt) of the bales. The total net mass of bales under test Mn = Mg - Mt Determine the total corrected net mass (M) of bales under test by the following formula : M = Mn X (100+ contract moisture. regain, percent) 100 + average moisture regain percent of bales. 4.2.2 Moisture Regain Determine the moisture regain of each cut / bag on opening the bales by the use of a suitable moisture meter. After opening the bales, sufficient time (not less than 10 minutes) shall be allowed to lapse before measuring moisture regain to enable the fabric to attain conditions for the normal use of moisture meter. Take at least 4 readings for each sample cut, 10 readings for each roll and one reading for each sample bag. Note - The average of all the readings is the moisture regains percentage of the bales. 4.2.3 Length & Width a) hessian i) Length -Determine the total length of the hessian in each selected bale by adding up the length of the cuts in the respective bales, measured correct to a decimetre after conditioning at the prevailing atmosphere. In case of rolls, determine the length of hessian in each roll in the test sample correct to a decimetre. ii) Number of Short Pieces ( for Bale only) - Determine the number of short pieces of hessian in each bale by measuring the length of the cuts correct to a decimetre by using either measuring table or measuring scale method.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 34

iii) Width- Determine the width of cuts correct to 0.5 cm after conditioning the same in the prevailing atmosphere. Take 3 width readings for each cut. In case of rolls, take 5 readings from each roll at interval of approximately one-fifth of the roll length leaving about 10 m from the ends. b) Bag Lay each bag flat on a table; remove all the creases and wrinkles and measure the outside length and outside width about the center of the bag to the nearest 0.5 cm. 4.2.4 Ends and Picks a) hessian Determine ends and picks per dm of each cut at one and two places respectively with a suitable measuring gauge, in accordance with IS 1963:1981. In case of hessian in rolls, count the ends and picks from each roll by taking two readings for ends and one reading for picks from every 100m or part there of subject to a minimum of two. Calculate the average ends and picks per dm. b) Bag Determine ends and picks per dm of each bag at one and two places respectively with suitable measuring gauge, (See IS 1963:1981.) Calculate the average ends and picks per dm of the sample bags under test. 4.2.5 Mass a) hessian Weight the cuts / rolls up to nearest 0.1kg / nearest kg respectively after measuring moisture regain and determine the mass in gram per square metre of hessian fabric at contract regain percent for each cut / roll separately from the corresponding percentage regain , measured length and nominal width of cuts / rolls. b) Bag Weigh each bag to the nearest 5 g after tests for bale mass and moisture regain. Correct the observed mass of each bag for the observed moisture regain as follows: Corrected mass = Observed mass X (100 + contract moisture regain, percent) 100 + observed moisture regain, percent 4.2.6 Breaking Strength (Warp way and Weft way) a) hessian From each cut or rolls prepare 10 test specimens, 5 in the warp and 5 in the weft directions and determine the breaking strength by following either ravelled strip method or grab method. b) Bag From each sample bag test two specimen each in warp way and weft way for breaking strength with 100 mm wide ravelled strips and 200 mm between grips ( See IS 1969:1985) 4.2.7 Breaking Strength of Seam (for Bag only) From each sample bag test two specimens each in warp and weft seam for seam breaking strength (See IS 9030:1979.) 4.4.8 Oil Content From each cut / roll or bag take two representative strips, together weighing approximately 20 g and determine the oil content on dry de-oiled material basis by extracting in tri-chlorethylene or light petroleum (See IS 2969:1974.) 4.2.9 Number of Joined Bags per Bundle and Bags per Bale Count the number of bundles in each bale and the number of bags and joined bags in each bundle. From the above determine the total number of bags in each bale under test. Part 3 - List of Test Equipments 4.3 The details of test equipments required are given in Annex VI.

SECTION V CERTIFICATION CRITERIA 5.1.1 Sample Size a) Fabric -10mX1m

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 35

b) Bags - For routine inspection unless specifically mentioned, based on the present practice followed, 30 bags are drawn preferably from three different bales irrespective of the stock or lot size with equal number of bags selected from each bale indicating serial number for identifying the same. However for lot inspection the criteria given in the respective standard is to be followed. Note- The sample may be wrapped with plastic sheet to prevent the loss of moisture. 5.1.2 Criteria for Conformity The sample shall be considered as conforming to the requirements of the relevant standard, if the following conditions as applicable are satisfied: A) hessian i) The total of the corrected net mass of the bales / rolls under test is not less than the total contract mass of the bales and within + 8/-2 percent in case of rolls. ii) The total length of hessian (cuts) in each bale / roll shall conform to the specified requirement in case of bale and within + 1 percent of agreed length in case of roll. iii) The number of short pieces (cuts) in each bale under test does not exceed the specified number. iv) The average moisture content percent of the test samples does not exceed the specified percentage. v) The average oil content percent of the test samples does not exceed the specified percentage. vi)The average warp way and weft way breaking strength values of the test samples either by ravelled strip test method or grab test method are not less than the corresponding breaking strength specified. vii) The average value of (a) mass per square metre (b) ends per decimetre, and (c) picks per decimetre for the test samples are in accordance with the requirements specified. Viii-a) Construction above (38x31) or (9x8) (see note) Not more than 20 percent of the width readings of the cuts under test are outside the specified tolerances and not more than half of these readings (10 percent) are below the specified nominal value. However, no individual reading shall fall below the specified nominal value by more than 0.5 percent subject to a minimum of 0.5 cm. Viii-b) Construction (38x31) or (9x8) (See Note) and below The average value of width is in accordance with the requirements specified, but no individual reading shall fall below the specified nominal value by more than 1 cm. Note - 38x31 stands for 38 ends / dm and 31 picks/ dm and 9x 8 stands for 9 porters and 8 shots. B) Jute Bags According to IS 1943, IS 2566, IS 3984 and IS 15138 i) The total corrected net mass of the bales under test is not less than the total of the contract mass of the bales. ii) The total number of bags in each bale under test is not less than the specified number. iii) The number of joined bags in each bundle of 25 bags is not more than one or 4 percent of of the total number of bags in a bale. iv) The average moisture regain percent for the bags under test is not more than 22 percent. v) The average oil content percent for the bags under test is not more than 3 percent. vi) The dimensions of at least 80 percent of the bags under test are in accordance with the requirements specified and dimensions of not more than 10 percent of the bags under test are below the specified nominal value by more than 2.0 cm. vii) The corrected mass of at least 80 percent of the bags under test in accordance with the requirements specified and mass of not more than 10 percent of the bags under test is below the lower specified limits. However, the average corrected mass of all the bags under test shall not fall below the specified nominal value. viii) The average ends and picks per decimetre of the bags under test are in accordance with the requirements specified. ix) The average warp way breaking strength and weft way breaking strength values for the bags under test are not less than the specified requirements. x) The average breaking strength of seam for warp way and / or weft way are not less than the specified requirements. C) Laminated Jute Bags for Packing Fertilizers I) Average bitumen content and other details of the bags tested for bitumen bonding satisfy the corresponding requirements specified. ii) The average liner mass of the bags tested satisfy the requirements specified. However not more than 10 percent of the bags shall have liner thickness lower than 25 percent of the specified thickness.

Draft manual for certification of UPVC pipes, MSN, 18 July 2006 36

iii) The dimensions of at least 90 percent of the bags under test are in accordance with the requirements specified. In the remaining bags, no bags shall have dimensions less than 1.5 cm. below the specified values. iv) The average breaking load for laminated fabric and seam conforms to the requirements specified. D) Jute for Packing 50 kg. Food grains. i) The total of the corrected net mass of bales under test is not less than the total contract mass of the bales. ii) The total number of bundles in each bale under test, number of bags and number of joined bags in two bundles from each bale under test meet the relevant requirement. iii) A bags shall be termed as defective if it contains two or more major defects. The sample shall be considered as conforming to the requirements of freedom from defects if the total number of defectives is less than or equal to acceptance number i.e. 2 for sample size of 30. iv) The sample shall be considered as conforming to the requirements of length, width, ends per dm , picks per dm, stitches per dm and moisture regain if the total number of defectives found in the sample is less than or equal to the corresponding acceptance number { see ( iii ) above }. v) The sample shall be declared as conforming to the requirement of mass if average value of mass per bag is not less than the nominal value specified and not more than 10 percent of the individual values of the mass of the bags are below the lower specified value. vi) The sample shall be declared as conforming to the requirements of breaking strength if average value of warp way, weft way and seam breaking strengths respectively, as obtained for all the test specimens are not less than the corresponding values specified. None of the individual value is less than 20 percent below the specified values. vii) The sample shall be declared as conforming to the requirement of oil content if all the bags tested meet the specified value.

IV SECTION OTHER ASPECTS 6.1 Scheme of Testing and Inspection The schemes of inspection and testing are given in annex VII A to VII E 6.2 Marking Fee Schedule IS No. & Year Name of the Product Unit Rate Rate of

Fee

1S1943: 1995 A- Twill jute bags 1 Tonne Rs 14.40 18000.00 LSU

12000.00 SSU

IS 2566:1993 B -Twill jute bags 1 Tonne Rs 14.40 24000.00 LSU

17000.00 SSU

IS 2818 Indian hessian; 305 & 1 Tonne Rs 12.00 18000.00 LSU

(Part 2):1971 229 g/m 2

12000.00 SSU

IS 3984:2002 DW. Flour bags 1 Tonne Rs 14.40 24000.00 LSU

17000.00 SSU

IS 7406 (Part 1):1984 Jute bag for packing 100 Bags Rs 1.45 24000.00 LSU

Fertilizers 17000.00 SSU

IS 7406 (Part 2):1986

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IS 12650: 2003 Jute bags for packing 50 kg Tonne Rs 14.40 29000.00 LSU

Food grains 22000.00 SSU

IS 15138: 2002

Jute bags for packing 50 kg 1 Tonne Rs 15.00 36000.00 LSU

Sugar 29000.00 SSU

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6.3 Testing Laboratories i) Indian Jute Industries Research Association, Kolkata ii) Eskaps (India) Pvt. Ltd. Kolkata 6.4 Testing Charges IS No. & Year Name of The Product Testing charges, Rs. 1S1943: 1995 A- Twill jute bags 2040 IS 2566:1993 B -Twill jute bags 1200 IS 2818 (Part 2):1971 Indian hessian; 305 & 229 g/m 2 1275 IS 3984:2002 DW. Flour bags -- IS 7406 (Part 1):1984 Jute bag for packing fertilizers 900 + 450 IS 7406 (Part 2):1986 Jute bag for packing fertilizers 875 + 450 IS 12650: 2003 Jute bags for packing 50 kg food grains 1275 IS 15138: 2002 Jute bags for packing 50 kg sugar 1140 6.5 Lot Inspection 6.5.1 hessian a) Sampling i) For assessing the conformity of bales or rolls to the requirements of IS 2818, the test sample of bales/ rolls shall be selected from the lot at random as follows: No. of Bales / Rolls in the lot No. of Bales/ Rolls to be Drawn and Opened for

Inspection Up to 15 2 16-50 3 51-150 5 Note - If the number of bales/ rolls in a lot exceeds 150, the same shall be taken as a separate lot comprising of bales/ rolls maximum up to 150. ii) From the bales/ rolls selected, the test sample shall be drawn as follows: Gross mass and tare mass (baling hoops or cores and All the bales / rolls selected all packing materials) Length of hessian per bale/ rolls 10 percent of the cuts in the bales selected to a minimum of 3 or all rolls selected. Number of short pieces per bale All the bales selected Moisture regains percent Ten cuts shall be Mass in g/m2 drawn covering all the Ends and picks per dm bales /rolls selected. Width Breaking strength One metre from each bales/ roll subject to a minimum of 3 m from 3 different cuts/ rolls Oil content, percent Two sample pieces from two cuts selected from two different bales / rolls b.) Criteria for conformity The lot shall be considered as conforming to the requirements if the conditions given in 5.2 (A) are satisfied. 6.5.2 Jute Bags conforming to IS 1943, IS 2566, IS 3984 and IS 15138 a) Sampling i) For assessing the conformity of bales in a lot to the requirements of relevant standard, the test sample of bales shall be selected at random as follows: No. of Bales in the lot No. of Bales to be Drawn and Opened for Inspection

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Up to 15 2 16 to 50 3 51 to150 5 151to 500 8 Note - If the number of bales in a lot exceeds 500, the same shall be taken as a separate lot comprising of bales maximum up to 500. ii) From the bales selected, the test sample shall be drawn as follows: Gross mass and tare mass 10 percent of total number of bales in the lot Tare mass (of bailing hoops and all other Te bales selected packing material) Number of bundles each bale The bales selected Total number of bags per bale Two bundles of bags Number of joined bags per bale from each bale selected Moisture regain, percent Ten bags (selecting equal number of bags) from each

bale selected. Length and width Ends and picks Mass per bags Breaking strength Five bags selected out of bales selected subject to a minimum of one bag each bale. Oil content, percent Two bags selected out of two different bales selected. Note: 1.) Joined bags shall not be selected for the purpose of tests for dimensions and mass of bag. 2.) In case the bundles contain less than 25 bags, five bundles shall be selected from each bale for determining the number of joined bags per bale. b.) Criteria for conformity The lot shall be considered as conforming to the requirements if the conditions given in 5.2 (B) are satisfied. 6.5.3 Laminated Jute Bags Conforming to IS 7406 (Part 1) & IS 7406 (Part 2): a) Sampling i) The number of trusses to be sampled from each lot separately for testing various characteristics shall be as follows Lot Size Sample Size for Inspection Up to 10 1 11to 20 2 21 to50 3 51to 100 4 101to 150 5 151to 200 6 201to 250 7 251to 300 8 301to 350 9 351to 400 10 401and above 10+1 for every 100 trusses or part thereof above 401 trusses ii) From each of the trusses selected, the test sample shall be drawn as follows Test Sample Size Length and width, ends, 10 percent of the selected bags Picks, type and number of stitches Bitumen bonding and liner 2 bags Breaking load 2 bags from each truss subject to a minimum of Fabric & Seam 5 bags in a lot b.) Criteria for conformity

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The lot shall be considered as conforming to the requirements if the conditions given in 5.2 (C) are satisfied. 6.5.4. Jute Bags Conforming to IS 12650: 2002 a) Sampling For assessing the conformity of bales in the lot to the requirement of the specification, the test sample of the bales and number of bags to be selected from each bale shall be as follows : No of Bales in Lot No of Bales Length, Width Number of Stitches, Ends, Picks, Moisture regains In Sample No of bags from Total Number of bags Acceptance No.

each bale. Up to 25 5 16 80 5 26 to 90 8 16 128 7 91to 300 13 16 208 10 301 to 500 20 16 320 14 b.) Criteria for conformity - The lot shall be considered as conforming to the requirements if the conditions given in 5.2 (D) are satisfied with acceptance of number of number of defectives as given in the above table. 6.6 Typical Test Report Typical performa for test reports of hessian and bags is given in Annex VII-A & B respectively.

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ANNEX-I A

Principal requirements of A –Twill Bags (IS 1943: 1995 with Amendments 1 to 4)

Characteristic Requirement Tolerance Sacking 2/1 twill weave jute sacking having nominal mass

of 750 g/m2 with warp running along the length and

three blue stripes or stripes as agreed woven along the length Dimensions, cm (See Note) Out side length 112 +4 Out side width 67.5 -0 Corrected mass per bags,g 1190 +120 -90 Ends per dm 102 + 6 Picks per dm 35 + 2 Average breaking load of sacking (Ravelled strip 10 cm x 20cm) Min. N (kg) Warp way 2000 (204) Weft way 1765 (180) Seam 657 (67) Number of overhead or herakle stitches per 10 cm on both sides 9 to 11 of the bag Number of safety union stitches 9 to 11 per 10 cm Freedom from defects Free from weaving and sewing defects Number of bags per bale 400 or as specified in agreement Number of joined bags per bundle 1 of 25 bags. Contract moisture regain, percent 20 Contract mass of bale, kg. 476 Corrected net mass of bale Not less than contract mass Moisture regain, percent, Max 22 Oil content on dry de-oiled material 3 basis, percent, Max Note - In case dimensions other than those specified are agreed, tolerance on dimensions as specified above shall apply and tolerance of + 10/-7.5% on the mass of bag as calculated by the method given in 5.3 of IS 9113:1992 shall apply.

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ANNEX-I B Principal requirements of B - Twill Bags (IS 2566: 1993 with Amendments 1 to 3)

Characteristic Requirement Tolerance Sacking Single piece of 643 g/m 2 fabric with preferably warp running along the length of the bag and single blue stripe of single or

double warp as agreed. Dimensions, cm (See Note 1) Bag Capacity 100 Kg. 93 Kg. 73 Kg. Out side length 122 112 106.5 +4 Out side width 67.5 67.5 61 - 0 Corrected mass per bag, g Overhead stitch 1110 1020 880 +10 % Herakle stitch 1115 1025 885 -7.5 % Ends per dm 76 + 4 - 3 Picks per dm 31 + 2 - 1 Average breaking load of cloth (Ravelled strip 10 cm x 20 cm) Min., N (kgf)

Warp way 1570 (160) Weft way 1620(165) Seam 608 (62)

Number of overhead or herakle stitches per 10 cm on both sides 9 to 11 of the bag Freedom from defects Free from weaving and sewing defects Number of bags per bale (see note 2) 300 Number of joined bags per bundle 1 of 25 bags. Contract moisture regains percent 20 Contract mass of bale, kg. (See note 2) Overhead Stitch 333 306 264 Herakle Stitch 334.5 307.5 265.5 Corrected net mass of bale Not less than contract mass Moisture regains, percent, Max 22 Oil content on dry de-oiled material 3 basis, percent, Max Note 1 - These bags are recommended for wheat, rice and similar coarse grains. For other materials dimensions other than those specified if agreed may be adopted. In that case tolerance on dimensions as specified shall apply. Note 2 - As per buyer requirement, total number of bags per bale may be 400 for 75 kg capacity with contract mass of bale as 354 kg for herakle stitch.

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Annex IC Principal Requirements of Indian hessian

[IS 2818 (Part II): 1971 with amendments 1 to 4] Characteristics Requirement Type I Type II - Mass per sq. metre, g 305+24.4 229+18.3 - 6.1 - 4.6 - Ends per dm 47+ 2 38 + 2, -Picks per dm 47+ 2 35 + 2, - Width, cm (see Note) 101.5 +3.0 101.5 +3.0 - 0.0 - 0.0 - Average breaking load, Min, kgf. a) Ravelled strip method (10cm x20cm) Warp way 112 92 Weft way 120 78 b) Grab method, Warp way 36 29 Weft way 39 25 -Contract moisture regain, percent 16 16 -Moisture regain, percent, max 17 17 -Contract weight of bale, kg * 566 425 Contract weight of roll/bale = nominal width (cm) x marked length (m) x weight (g/m2) 100 X 1000 - Corrected net weight Not less than contract weight Net Weight x (100+ contract moisture regain) 100+ Average moisture regain percent - Length of hessian, m, Min 1829 - Permissible number of short pcs. @ Per bale 3 - Oil content on dry de-oiled. 3 material basis, percent, Max. * Based an 101.5 cm nominal width and marked length of 1829 m @ Short piece is a length of continuously woven jute fabric measuring 18m or more but less than 82 m. Note- Width of hession shall be 101.5 cm or as specified in the agreement between the buyer and the seller, if agreed width is below 101.5 cm, the tolerance shall be +3.0 cm and if the agreed width -0.0 of hession is above 101.5 cm, the tolerance shall be +3 percent. -0

ANNEX-I D

Principal requirements of DW Flour Bags (IS 3984:2002 with Amendment No.1)

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Characteristic Requirement Sacking Single piece of double warp, plain weave jute sacking with

warp running along the length of bags and without stripes or stripes as agreed woven along the length of bag

Dimensions, cm (See Note 1) Out side length 142 +4 Out side width 71 - 0 Corrected mass per bag, g 1143 +10% -7.5% Ends per dm 68 + 4 - 2 Picks