Clubbing Entrepreneurially: Inside India’s FMCG Giant

The Industry Collaborations Vertical of the Ashoka Business Club organised a field visit to the Bikano (Bikanervala) Manufacturing Plant in Jewar, offering students an immersive look into the scale, science, and precision behind one of India’s most beloved FMCG brands. What unfolded was a day filled with learning, sensory experiences, and a deeper appreciation for how everyday snacks are produced on an enormous scale.

Long before we stepped into the facility, the experience had already begun. The bus ride was filled with conversations, laughter, and students sharing stories about past field visits, setting the tone for a day of curiosity and excitement. By the time we arrived, the group was buzzing with energy.
The Bikano factory, spread across 25 acres, represents modern manufacturing at its finest. Despite only 50% of the site being built so far, the plant already handles an impressive 150 tonnes of production across bhujias, namkeens, chips, and snack mixes. Constructed in 2023, the facility is a blend of tradition, innovation, and large-scale efficiency.

From the moment we walked in, we were welcomed by the warm, layered aroma of spices, sometimes sharp, sometimes savoury, but always unmistakably “Bikano.” It felt as though the masalas themselves were greeting us.

One of the highlights of the tour was watching how Bikano’s iconic products come to life. The group was fascinated to learn that the Bikano bhujia is still made partially by hand, preserving its authentic texture and flavour through old-school craftsmanship. Watching workers handle the dough, press the bhujia mix, and control the frying process was reminiscent of the behind-the-scenes episodes many of us had seen on TLC growing up.

In contrast, snacks like Aloo Bhujia are produced entirely by automated machinery. We saw extrusion lines, massive fryers, cooling conveyors, seasoning drums, and high-speed packaging machines, all running in perfect coordination. Seeing raw potatoes transform into perfectly flavoured aloo bhujia within minutes offered a powerful demonstration of how traditional recipes scale up through modern engineering.

Another standout moment was our visit to the quality testing laboratory. This is where batches are tested for aroma, flavour, crunch, moisture levels, and consistency before they receive approval. Watching technicians perform scent-profile checks and structured tasting tests, almost like scientific rituals, was fascinating.

For many of us, it was the first time we saw concepts from high-school chemistry labs, like titration, being used in a real industrial setting with high stakes. It gave us a deeper appreciation for the intersection of food science and quality assurance.

Across the factory floor, we observed an extraordinary level of cleanliness, hygiene, and monitoring. We learned how everything, from the thickness of a chip to the distribution of masala in namkeen, is measured and controlled in real time. Every step reflects the brand’s commitment to consistency, safety, and flavour.

As the visit concluded, the Bikano team surprised each student with a curated selection of fresh products, a small yet thoughtful gesture that left everyone smiling.

For many students, this field trip was more than a tour; it was a powerful lesson in operations, supply chain management, entrepreneurship, and the discipline required in large-scale food manufacturing.
It reminded us that behind every packet of bhujia or chips lies a complex chain of decisions, technologies, human expertise, and rigorous quality checks. The experience also reinforced core entrepreneurial values:

• Consistency matters.
• Innovation must complement tradition.
• Hands-on problem-solving is essential.
• Growth must never compromise quality.

The Ashoka Business Club looks forward to organising many more such experiences, bridging classroom learning with real-world industry exposure.