Shan foods

1. History

Shan Foods (Pvt) Limited started off in 1981, as a cottage industry operation, operating out of
the home of the company's founder Sikandar Sultan. He, along with his wife, started making
spice mixes at their home, experimenting extensively to come up with unique offerings, which
instantly picked up a loyal fan base both, at home and with South Asians who had moved to
Western Countries, such as USA and Canada.
Today, Shan Foods is one of Pakistan's largest manufacturers and exporters, and their offered
range is considered synonymous with the traditional authentic taste of the subcontinent coupled
with convenience and ease.i

2. Vision and mission

Shan to become an iconic culinary brand enjoyed on every table everyday across the world.

3. Quality objectives

Shan Foods, upholding quality is the base of what we stand for. We strive to set our Quality
Operations as a benchmark for the industry at large.

Our mission is to provide our consumers with supreme standards of product quality, safety and
consistency.

Our Quality Control department regularly monitors the different phases of production from
research & development to packaging while conforming to national and international regulation
and legislation. This ensures highest quality at each stage of production for our consumers to
safely enjoy our food products.

4. Policies

SHAN FOODS Limited is dedicated to provide a workplace that is safe and secure and provides
a respectable working environment for all of our employees. Shan Foods Private Limited also
believes in minimizing the environmental impact in our business activities. Management and
Employees of Shan Foods Private Limited is thus directed to achieve these goals by:

1. Ensuring that the business meets all obligatory requirements.

2. Developing and maintaining systems to manage our Health, Safety and Environmental programs
at all levels of the organization.
3. Setting clear targets for continual improvements and monitoring these targets to ensure that they
are being achieved.
4. Striving our best to ensure that we operate, and assess our facilities, ensuring the protection of
the environment within our facility and around us, and for the protection of the Health and Safety
of our employees, contractors, visitors and others.
5. Develop and implement effective HSE risk management system focusing on elimination and/or
otherwise reduce HSE risk to an acceptable level (Including Environment Impacts).
6. Focus on green practices, pollution reduction, optimize energy efficiency and manage waste
through 3R's methodology (Reduce, Reuse and Recycle).
7. Ensuring consultation and participation of workers in development, implementation and review
of HSE management system.
8. Providing training, motivating and engaging employees so that they understand their HSE
responsibilities and participate actively in the HSE Programs to promote HSE culture.
9. Periodically evaluate audit and assess our HSE performance against stated goals and principles
10. Effective communications to relevant stakeholders and interested parties on applicable HSE
Related matters.
We as Management of Shan Foods Private Limited is committed to this Health, Safety and
Environmental Policy. We will ensure that this policy is available, understood and implemented
throughout our facilities.ii

5. Context of organization:

1. Issues
1.1. Internal issues
 Aging workforce and new hires
 Formation of a labor union
 Relocation of the company

1.2. External issues

 Loss of a key supplier
 Technology shifts
 Oil price changes

2. Interested parties:
 Customers: The requirement of the customers is to provide them quality product
with a price that justifies with the quality of product. Our organization is serving
our best to ensure the requirements of our customers are fulfilled.
 Owners: They are considered as interested parties as the increase or decrease in
market share, revenue and profitability will affect them directly. Shan foods
covers major portion of the food market which means owners are in good position
as interested parties.
 Employees: The needs and expectations of employees is to provide continuation
of job, timely wages and growth in their knowledge, the following requirements
are fulfilled in our organization with several training programs, seminars and
training sessions timely.
  External providers: Shan foods maintain a long term relationship with our
providers and timely payments are received by them for the good and services we
take, which is the basic requirement of them as interested parties.
 Competitors: Their requirement is to maintain a larger market share.The IT
Managers of our organization are on their duty to do regular market research on
our competitors their services and pricing.
6. Scope of the quality management system:

“New Product development, production, R&D to packaging of our iconic range of products all
steps are covered under the scope of quality management principles.

The distribution department although is under supervision of the company but it is not included
in the scope of QMS at present times.”

Product: Shan Shoop noodles

7. Processing flowchart:
 8. Processing:

Noodle is a widely popular food item, with a distinct and delicious taste. However, the process
that goes into making instant noodles is not that easy. In here, we will see the process of instant
noodles manufacturing.
Step by Step process
 Knead and Mix: As a first step, the wheat flour and water goes into the mixing machine
in the noodles manufacturing process. Here, dough is kneaded with about 0.3 to 0.4kg
water at a temperature of 20 to 30 degree Celsius, thus providing the dough with tissue
generating elastic feature for the noodles.
 Creating noodle belt: Then the dough goes into two rotating rollers wherein two noodles
belt is bought together as one belt, helping to distribute the noodles evenly. The dough is
also left for a specific time to mature.
 Rolling: With the help of pressing rollers, the 10mm thick noodles is flattened repeatedly
using four rollers and finally becomes thin at 1mm thickness.
 Slitter: To add to the noodles manufacturing process, these noodles is then put into the
slitter, where with the help of roller blades these instant noodles are made even thinner
and wavy.
 Steamer: Then is the pre-gelatinization process in the steamer, where the instant noodles
is steamed for one to five minutes.
 Dipping bath: Then the steamed noodles are dipped in seasoning.
 Feeder: Then it is cut as long as 40-70cm then molded using a round- or square- shaped
metal mould serving
 Dehydration process: Most of the noodles are dehydrated either by oil frying or air
drying, thus giving rise to fried or non-fried noodles. There are also the steamed noodles
that are known as Raw-type instant noodles.
 Cooler: Following the dehydration in the noodles manufacturing process, the noodles that
are at 100 degree Celsius is cooled with air.
 Check weight and detect metal: In case any metal is detected in the noodles or if the
weight is beyond the preset range, the product is then discarded.
 Packing: The ready instant noodles are then put into firm bags or containers as required
along with the garnish and seasonings and then sealed with aluminum foils. iii

9. Raw material ,their test and specifications:

The main raw materials of instant noodles are wheat flour and palm oil. The wheat flour
is mixed with water and other ingredients to form a uniform dough, then pressed into
noodles, cut into noodles, and then deep-fried. The golden and crisp instant noodles are
made, and the taste is delicious. Very rich. In order to prolong the shelf life, most instant
noodles will be fried and oxidized into oxidized lipids, which will accumulate in blood
vessels or other organs, accelerating the speed of human aging and causing
atherosclerosis.

In addition, some phosphates are added to the noodles. Although phosphate additives can
improve the taste of instant noodles, if the body takes in too much phosphorus, the body’s
calcium cannot be fully absorbed and utilized, which can easily lead to fractures, tooth
loss and bone deformation. Since instant noodles are a kind of food with very large
demand, in order to extend the shelf life, instant noodles will be added with antioxidants.
The antioxidants will be affected by the environment during long-term storage, which
will cause harm to the human body.

The main raw materials in the instant noodle seasoning package are meat, aquatic
products, vegetables, fillers, seasonings and fats, etc. Adding it to the instant noodles can
make the noodles more delicious. But everyone needs to pay attention to that the salt
content in the seasoning packet is very high. A packet of instant noodles contains about 6
grams of salt, and a person’s daily salt intake should be 6 grams. If you eat instant
noodles for three meals a day If it does, it will allow our body to take in a lot of salt,
which will easily cause high blood pressure and damage the kidneys.

Therefore, although instant noodles are rich in carbohydrates and saturated fatty acids,
they lack nutrients such as protein, calcium, iron, zinc and vitamins, and also contain
some harmful substances. If they replace regular meals for a long time, they will
inevitably cause malnutrition.iv
 10. Packaging, their test and specifications:

Packing film used for packing:

 PET( polyethylene terephthalate)+MPET(metalized polyethylene terephthalate)

+PE(poly ethylene)
 Used for primary packaging
 PET( polyethylene terephthalate)+Aluminum foil + PE(polyethylene)
 Used for secondary packaging

Performing test for packing film:

180 degree Peel Strength Test:

 Dipping the packing film in ethyl acetate

 Taking the value of strength of film by tensile tester

Heat seal test:

 First sealing the packing material

 Then testing its value of strength in N/m2

BCT (Box Compression Tester) tester:

 Placing the box for compression in BCT

 Allow the tester to compress the box
 The value will be in Newton(N)

11. HACCP system implementation

Detailed flowchart:
Determination of CCPs:
The following CCPs are determined by the detailed analysis of the processing of shan
shoop noodles.
I. Raw material checking
II. Sifting powder
III. Acid soaking
IV. Metal detection
V. Sterilization
VI. semi product checking
HACCP plan:

CCPs Hazard Critical control document Respons Correct Verifica

limits ation ible ive tion
personn actions( procedu
el for re
exceedi
ng
limits)
raw Biological, Specifie Certified Certificate Receivin Reject Regular
material physical, d supplier of analysis g or as view of
checkin chemical toleranc with designat supplier records
g e for HACCP ed and
each program operator supplier
item
sifting Physical(metal Sift net Checking Certificate operator Replace regular
powder and other is good sift net of analysis the sift view of
foreign net records
matter)
Acid Biological(pat Acid Checking Record Soaking Adjust Regular
soaking hogen growth) solution acid pH Acid ph operator pH and view of
pH of after 20 time records
2.7-3.1 min
Acid Acid Record
soaking soaking acid
time of time soaking
≥ 36 sec time each
shift

metal Physical(metal Free of Complian Continuous Metal Reject Regular

detectio inclusions) metal ce with monitoring detecting unqualif view of
n matter product of metal operator ied records
specificat matter product
ions
Steriliza Biological(pat Noodle Noodle Record Sterilizat Adjust Regular
tion hogen growth) temperat temperatu noodle ion tempera view of
ure re after temperatur operator ture and records
of≥90C sterilizati e after one time
on hour
Steriliza Sterilizati Record
tion on sterilizatio
 temperat temperatu n
ure of≥ re temperatur
94C e after 30
min
Steriliza Sterilizati Record
tion on time sterilizatio
time of n time each
≥ 30 sec shift
Semi Biological Free of Semi Record operator Reject Regular
product (pathogen unqualif product whole unqualif view of
checkin growth) ied semi- ied records
g product products product
i
https://en.wikipedia.org/wiki/Shan_Foods#:~:text=Shan%20Foods%20(Pvt)%20Limited%20is,the%20packaged%20spice
%20mixes%20industry.

ii
https://www.shanfoods.com/

iii
https://marutinoodlez.wixsite.com/noodles/single-post/2016/10/04/step-by-step-process-of-instant-noodles-
manufacturing

iv
https://www.paspk.org/wp-content/uploads/2016/10/Rice-Noodles.pdf