Nilgiris, which may have started as a small bakery in 1905 is now one of the most mechanized bakeries. It is the only bakery to have a "puff sheets" preparing machine, which rolls out 72 alternative sheets of dough and hydrogenated fat in 35 minutes. The present production capacity being approx. 6,000 puffs per day on average. What was impressive as to how organized the entire process was--
Mixing with mechanized systems for proportion and texture
Refrigeration to prepare the moulds
Cutting machine for cookies-shape-wise
Baking-different machines for different products or batch-wise bake facilities
Blast refrigeration for products which need to be stored or transported.
Cold storage
Nilgiris is a preferred brand in Karnataka, now spread across entire south India. However, what I noticed that the scale was not that of what could be expected of a century-old bakery. Whether it is a deliberate effort to stay small or they are unable to scale and expand is the question to be asked. One may say that how does it matter but this could lead to the underlying reason why Nilgiris still faces tough competition from the Britannias and the Sunfeasts.
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