UNIVERSITI TENAGA NASIONAL

MEFB213
MANUFACTURING PROCESSES

INDUSTRIAL VISIT REPORT:

MAMEE-Double Decker (M) Sdn. Bhd.

_________________________________

SECTION :4
LECTURER : HJ. ZAINUDDIN BIN YAHYA
GROUP MEMBERS :

NO. NAME ID
1. RADJHAM BIN ABRAHAM ME096008
2. AHMAD KHAIRUL ASYRAF BIN KHALID ME095375
3. MOHD SYAFIQ BIN MOHD FAUZI ME095818
 CONTENTS
NO. CONTENTS PAGE
1. Introduction 2
- Corporate profile
- Company achievements
2. Process flow 3 – 12
- Mixing 4
- Rolling 5
- Slitting 6
- Steaming 7
- Cutting 8
- Frying 9
- Cooling 10
- Packing 11 - 12
3. Discussion 13
4. Conclusion 14

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 INTRODUCTION
Manufacturing processes (MEFB213) is a core subject for all mechanical students.
Different manufacturing processes of the past, present and future are used in different field of
companies. Throughout this course, there are many manufacturing processes including casting,
welding, grinding and many more. Besides, this course provided the student to in doing a
project which required a visit to a manufacturing company to observe the processes involved
in manufacturing raw materials to a finished products. Thus, MAMEE-Double Decker (M)
Sdn. Bhd. were chosen. MAMEE-Double Decker (M) Sdn. Bhd. factory was located at Air
Keroh Industrial Estate, Ayer Keroh, Melaka. Based on observation, the factory uses different
kind of manufacturing to produces household food. During the visit to the factory, many useful
information about the manufacturing processes of raw material to finished products were
gained. It has been very interesting to witness the real process studied in the course during the
visit.

CORPORATE PROFILE
MAMEE-Double Decker (M) Sdn. Bhd. is principally engaged in manufacturing and
marketing of fast food and beverages. Founded in 1971, MAMEE-Double Decker or better
known simply as MAMEE has been established itself as a household name for food and
beverage serving over 50 products. MAMEE is a Malaysian based company with interests in
the manufacturing, marketing and distribution of snack foods, beverages, and other products
that exports to around 100 international countries, under the slogan "A World of Good Taste"
and is very popular in Australasian areas like Singapore, Indonesia and Australia. As of 2015,
the company headquarters is in the Air Keroh Industrial Estate in Melaka, Malaysia and it has
an office in Subang, Selangor. As of 2008, it has its registered office in City Plaza in Johor
Bahru.

COMPANY ACHIEVEMENTS
It is said that one must truly believe in themselves if greatness is desired. For over 44
years, MAMEE-Double Decker (M) Sdn. Bhd. has achieved global recognition as one of the
key suppliers in food and beverages for international export through a few simple yet fastidious
beliefs: "To truly resonate as a brand with the consumers, we have embarked on a journey of
delivering quality products consistently at an affordable rate." MAMEE-Double Decker has set
up manufacturing facilities in Myanmar and Indonesia in addition to its production location
here in Malaysia. All facilities have been awarded ISO 9000s, HACCP and Halal certifications.
Dedication to the industry has led MAMEE-Double Decker to win the Frost & Sullivan
Award for Best Home-Grown Packaged Food Company (2013 & 2014), and a Putra
Brand Award under the Foodstuff Category (2014). Last but not least, MAMEE Chef has
been rated in the Top Ten Instant Noodle category consistently by the Ramen Rater.

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 PROCESS FLOW
In all manufacturing industries, process flow is the most important thing in order to get
a good final product. Here, process flow means all the steps involved to form a final product
from the raw material. When carrying out the manufacturing process, workers should observe
the smoothness of machine's operation because any mistakes in the process flow can cause
accident and also can affect the final products. The affected final product cannot meet specific
requirement and finally the product will be rejected. So, the workers must always keep an eye
on the machine or be very careful when carrying out the process flow in manufacturing the
products.
According to this project, the raw material is flour and it will undergo several
manufacturing processes:

MIXING FRYING COOLING

ROLLING CUTTING PACKING

SLITTING STEAMING

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 PROCESS FLOW
MIXING
Firstly, the flour, water, egg and several ingredient were put into a mixing chamber to
make it into dough. The flour are mixed and sieve by an automated machine which have metal
detectors and magnets. The metal detectors and magnets are used to ensure that there are no
metal contaminants in the flour which will cause harm to consumers. The flour is sieved to
remove any lumps of flour that will affect the quality of the product. Reason that MAMEE's
noodles are chewy and would not become soggy (wet and soft) unlike other brands is that there
is also protein in their ingredients. Protein composition expressed as dough strength. The
ingredients are mix in the mixing chamber for about several minutes to get the best result. The
picture of mixing process was taken as shown by Picture 1.

Picture 1: Mixing process on the progress

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ROLLING
Second, when the dough is formed, it will be roll into a rolling machine. The purpose
of this stage is to flatten the dough to get an even thickness. Rolling also require to achieve
pulled noodle texture. The rolling machine will compress the dough into sheet and put through
a rotating rolls. The dough undergoes several rolling process and finally it will become 0.8 mm
in thickness. The picture of rolling process was taken as shown below by Picture 2.

Picture 2: The thick dough is roll into a rotating rolls

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SLITTING
After that, the sheets of dough will undergo slitting process. This process will cut the
dough to make it easier for the upcoming processes. Right after slitting, the dough undergoes
a roller with a wavy stamp to make the wavy characteristics on the noodle. This is the part
where Mi Tarik is made. The machine use is to imitate the La Mian technique (art of pulling
noodles) for better noodle texture. With this technology, the noodles will be able to go through
pulling and folding process like La Mian noodles. The noodles need to be rinse under cold
water before it goes through the pulling and folding process. Picture 3 shown below where the
slitting process was carried out.

Picture 3: Rolled dough undergoes the slitting process

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STEAMING
Steaming process is used to pre-cook the dough before it is fried under high temperature
to give the crispy texture and to reduce the water activity to prevent it from spoiling. Steaming
the dough is also to improve the texture by gelatinizing the starch in the dough. The dough is
steamed at the temperature of 120 degree Celsius for about 4 minutes long. For MAMEE
Snack, all the process are the same until this stage where the snack noodles are drenched with
chicken soup to give flavor to the snack. Picture 4 shown below where the steaming process
carried out.

Picture 4: Steaming process carried out after the process of slitting finished

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CUTTING
Next, this process will cut the noodles into required shape. In this case, there are two
line of work, one is for MAMEE Noodle Cup and the other one is for MAMEE Snack. For
MAMEE Noodle Cup, the noodles are cut according to the shape of the cup which is cylindrical
shape. As for MAMEE Snack, the noodles are cut into rectangular shape. Pictures below shows
the workers inspect for irregularities.

Picture 5: The workers are wearing proper attire to regulate the cutting process

Picture 6: Cutting process for MAMEE Noodle Cup

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FRYING
After cutting process, the conveyor runs the noodles into a frying machine. The noodles
are fried to a temperature 145 to 165 degree Celsius in 3 minutes. Picture 7 below shows the
frying process carried out.

Picture 7: The noodles undergoes frying process after cut into desired shape

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COOLING
Cooling process is required to cool down the temperature of the noodles before the
packaging process start. The noodles are cooled immediately to retain the texture from frying
the noodles and also to make sure that the noodles are cooled completely before the packaging.
If the noodles are still hot, it will complicate the workers to pack them and may damage the
packaging wrap. Picture 8 and 9 shows cooling process carried out.

Picture 8 & 9: Hot noodles undergoes the cooling process to maintain its temperature

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PACKING
The last part, packing. The noodles are fried and cooled immediately before they are
packed. Packing usually require the workers to wear a glove. But here, they does not wear any
glove. This is because, it is easier to examine the noodles for faulty and to inspect the shape.
Any damaged noodles are removed from the conveyor. The workers wear different color of hat
to differentiate their position and work they have to do. After packaging into the respective
packets, the products are then packed into cartons to distribute all over Malaysia. Pictures
below shows packing process in the making.

Picture 10: MAMEE’s workers are packing the ready-form noodle into desired pack

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Picture 11: The packing process is very systematic and in segmented sections

Picture 12: MAMEE’s workers are ready to pack the ready-form noodles

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 DISCUSSION
Food processing is a process in which several raw material are turn into delicious, edible
food. Food with variety of appearance depends on the efficiency of the manufacturing process.
Many food company would spend thousand for a technology that could enhance the flavor of
the manufactured food or beverages. In this modern era, all the process flow will involve
machines to run the operations. This would increase the productivity and reduce the chance of
failure. Besides that, there is no need for a lot of manpower.
In this project work, the main raw material is the flour. It undergoes several
manufacturing process as mentioned in process flow to turn into final product. MAMEE-
Double Decker (M) Sdn. Bhd. produce snack based food and MAMEE have been supplying
food locally and internationally. MAMEE products such as Corntoz, Nutrigen and MAMEE
Instant Noodle are Malaysian largest snack and beverage brand. From the company visit, many
types of the machine and how the process is being carried out were explained. Flour, as the
main raw material of the product. High quality flour was used to make the product delicious.
The flour will go through inspection, which only the good and preserved flour will be use for
the process. The stiffness of the noodles vary widely, not only as a result of the raw materials
used, but also as a result of steaming and frying. A lack of knowledge of these aspects has from
time to time led to improperly made noodles and gained snacks a bad reputation. So, in order
for a person to work in manufacturing industries, one must have knowledge on how to operate
the machines and the way the process all being carried out. Lack of knowledge may lead to
accidents.
Talk about the processes, one of the main process in this project is the mixing process.
In the mixing process, it is a process where 75 tons of wheat flour, oil, water and several more
ingredient are mixed to become a proper dough. The mixing process is done by an automated
machine, supervised by a worker. After that the dough will undergo rolling process where the
dough will be roll into 0.8 mm thickness. The roller exert forces to make the dough layered
accordingly to its specified thickness. Among the advantages of rolling process is that it can be
apply in slitting, and cutting process but with different type of roller. To improve the qualities
of machines, inspecting regime is done in 6 month period or 12 month period. An inspector is
responsible to monitor the work of the machines according to the specified period. The RM80
million production line machine operates excellently as it can produces 600 packs of MAMEE
Snack per minute. Daily, MAMEE produced 2.3 Million of instant noodles per day. Note that
process flexibility and special machines allow MAMEE to become a great local and
international food supplier.
Finally, from the visit to the company, MAMEE emphasize on material and dimensions
used during the packaging process. No matter how perfect the final product is, it will be rejected
if the dimensions does not meet the requirement. The final products only be valid if the final
product pass the quality control. If not, it will be rejected. So, a worker must be concern on the
quality of the final product too.

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 CONCLUSION
Throughout the visit to the company, extra knowledge is obtained on manufacturing
which it is an industrial activity that converts raw materials to useful product by the ways of
machines. Food manufacturing is one of manufacturing process which the raw material
undergoing several process to become edible foods. In this visit, a lot of food manufacturing
process types require to converts the raw material to the final finish products.
From the types of the manufacturing process, all of the process are crucial to make an
excellent product. Starting from mixing, the raw material are mixed together to obtain the
perfect combination of dough. Then, the dough undergoes rolling process and next to slitting,
steaming, cutting, frying, cooling and lastly packing. This is a very significant experience that
can be achieve only by watching the real process. It actually help the student to understand
more about the theory parts in this subject.
Besides all this, in manufacturing process industries, one must take into consideration
about the finishing step to produce the parts which we need to follow the exact specification
and details required by the customers. This is very important because if the desire of the
customers is not satisfied or something going wrong during the process, the product will be
rejected and it will be a waste of money and time.
In addition, this visit have exposed modern technology equipment for manufacturing
process. This manufacturing visit and project are very beneficial and significant for students as
the student have seen how proper, standard manufacturing is done by this established company.
All this knowledge will be very useful for students especially for the future career.
Finally, thanks to Hj. Zainuddin bin Yahya for giving such expensive information on
what manufacturing is all about. He has done the best for the students, his method of teaching
has spark some interest in manufacturing for the students.

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