Starting small

By Hiranthi Fernando

Two girls in green checked uniforms, complete with dark green apron, caps, masks and gloves were at work in the simple but well equipped little workroom which was scrupulously clean.

One girl stood by an industrial mixer in which a dough was being mixed. The other lightly oiled a set of shallow moulded trays. The finished product would go into the market as “Chummy”, a nutritious baby rusk which compares very favourably with the well known imported product “Farley’s Rusks.”

Supervising the girls at work was Mrs. Asoka Hettige, who initiated this little enterprise.

Mrs. Hettige, the mother of three young daughters was a graduate teacher with over 20 years experience as a teacher. Having graduated from the Colombo University in 1969, she completed a post graduate Diploma in Education in 1982. She opted to retire in 1990, under the special voluntary retirement scheme due to family commitments.

An avid reader, she read Sinhala translations of many well known authors. “From my reading I learned that one should make use of ones capabilies,”Mrs. Hettige said. “Although I gave up my profession, I realised there was other work I could do.” Having made up her mind to embark on a self employment enterprise, Mrs. Hettige visited the Ceylon Institute of Scientific and Industrial Research (CISIR) for assistance. She studied the available Technology Transfers in search of a suitable project. Her aspiration was to manufacture a product that would be both useful and new rather than manufacturing items like jams and jellies which were plentiful in the market. She finally settled for a project to manufacture baby rusks.

Having selected the project, Mrs. Hettige purchased the technology transfer from the CISIR for Rs. 20,000/=. “Details of machinery required, raw materials and the manufacturing process were supplied by the CISIR,” she said. “I also spent a full day with them in practical training. Mrs. Damitha Rajapakse as well as the other research officers in the Food Technology Division of the CISIR helped me immensely with information on the project, even giving me tips on cleaning the machinery, maintaining hygienic conditions and so on.” Mrs. Hettige says that her husband who is an officer in government service is also very supportive and helps her in the project.

Before she embarked on the project, Mrs. Hettige followed a two weeks course on Skills Development and Management conducted by the Sri Lanka Business Development Centre in collaboration with the German Agency for Technical Cooperation. She found this course also very useful.

Mrs. Hettige who introduced the baby rusks to the market in February this year, said she had started working on the project about an year earlier. They first put up a two roomed extension to their house at Athurugiriya. The construction cost her about Rs. 150,000/-. The total expenditure on the project was around Rs.400,000/-. Using her commuted pension and some money they received as compensation for part of their land which was acquired, they managed to cover this cost. She manages the production with three employees at present.

Explaining the production Mrs. Hettige demonstrated how a mixture of flour, sugar, a rising agent and some water is initially beaten in the large mixer. After mixing for ten minutes, water, vitamins and flavourings are added and beating is continued. When sufficiently beaten, a whisk is fitted to the mixer and the dough is whisked for aeration. It is then put into a moulding machine, which has been locally turned out to suit the requirements. Meanwhile, the oiled baking trays are placed in readiness, covered with mesh food covers. Placing the trays one by one below the plastic nozzle of the moulding machine, the mixture is poured on to the moulds guided by the girl operating the machine.

A batch of dough fills two large trays each containing six baking trays. The two trays are then placed in the oven and baked for ten minutes. The gas oven she uses has been manufactured locally. While this batch is baking in the oven another batch of dough is mixed and moulded. After baking, the rusks are placed on a rack containing wire trays, covered over with food covers and allowed to cool. Finally they are packed in foil, sealed in a triple sealer and put into cardboard packs.

Mrs. Hettige, also clad in apron, cap, mask and gloves, supervises the work to ensure that hygienic conditions are maintained at each stage of production. .

Mrs. Damitha Rajapakse, a Senior Research Officer of the CISIR said the Institute had analysed the imported baby rusks available in the market and developed the technology to manufacture a similar product at a more affordable price to suit the average local consumer. They had monitored the project run by Mrs. Hettige, and found that the hygienic conditions were being maintained.

Fifty packs of 200 grams are made each day. In addition to the original formula, apple and banana flavoured rusks are also manufactured. The nutritious rusks contain 81% of Carbohydrates together with Protein, fat, vitamins, minerals, Calcium and Iron. The packs are sold at Rs.85/- for the original and Rs.95/- for the flavours.

Depending on the response from the market, Mrs. Hettige has many plans for future expansion and improvement.

“However, before I expand further I have to first assess the market and work out the profitability of the project,” Mrs. Hettige said. She is trying to increase sales by making available a smaller pack in Aluminium foil wrapping which could be sold cheaper. Orange flavoured rusks are also on the cards. She works hard and is hopeful that her product which is of a high quality would earn a favourable response from satisfied consumers.

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