Mehran Bottlers (Pvt.

) Limited is a Pakistani corporation, manufacturer and retailer of carbonated

beverages, syrups and juices. The company is best known for its flagship product Pakola which was
launched on 14th August 1950, and for its toll manufacturing services.

It is the only company in Pakistan to make such wide range of products in various packaging i.e. PET,
tetra, cans etc. The company operates one of the most modern can filling plants in Pakistan, producing
top of the line cans readily available for consumption. MBL offers an all-round service by providing
experience, quality and reliability from a single source. MBL provides private label options for
carbonated drinks, juices and mineral water in PET bottles, cans and Tetra Pak; offering assistance from
the initial planning stage to full-scale beverage production. MBL has all the necessary facilities to create
the highest quality beverage solution for its consumers

Mehran Bottlers (Pvt.) Limited is pleased to offer its expertise in Toll Manufacturing to its national and
international clients. They include the following:

 Flavor Chemistry
 Application Development
 Brand Creation
 Regulatory Compliance
 Production
 Quality Assurance
Outsourcing to MBL not only gives you access to our expertise but also saves valuable time and
investment.
PRODUCTS
 Pakola Cream Soda
 Pakola Fresh Lime
 Pakola Lychee
 Pakola Pomegranate
 Pakola Pure Water
 Apple Sidra
 Vimto
 Forest Club Soda

CERTIFICATIONS
 (ISO 9001: 2000),
 (ISO 14001: 1996)
 (RVA HACCP)
 PSQCA CERTIFICATION
 HALAL CERTIFICATION

MISSION
Aim to spread the taste of Pakistan all over the globe by providing consumers with premium quality
beverages with a vast variety of products that guarantees consumer satisfaction in taste, flavor, product
safety and price competitiveness

VISION
To be a distinguished and trusted beverage company in Pakistan and are committed in fulfilling our
promise of providing international quality beverages made with the finest ingredients for all our
consumers worldwide.
 AOVERVIEW OF A BEVERAGE INDUSTRY

PRODUCTION OF A SOFT DRINK

Raw Materials
Carbonated water constitutes up to 94% of a soft drink. Carbon dioxide adds that special sparkle and
bite to the beverage and also acts as a mild preservative. Carbon dioxide is a uniquely suitable gas for
soft drinks because it is inert, non-toxic, and relatively inexpensive and easy to liquefy.

The second main ingredient is sugar, which makes

up 7-12% of a soft drink. Used in either dry or liquid
form, sugar adds sweetness and body to the
beverage, enhancing the "mouth-feel," an important
component for consumer enjoyment of a soft drink.
Sugar also balances flavors and acids.

The overall flavor of a soft drink depends on an

intricate balance of sweetness, tartness, and acidity
(pH). Acids add a sharpness to the background taste
and enhance the thirst-quenching experience by
stimulating saliva flow. The most common acid in
soft drinks is citric acid, which has a lemony flavor.
Acids also reduce pH levels, mildly preserving the
beverage.

Very small quantities of other additives enhance

taste, mouth-feel, aroma, and appearance of the
beverage. There is an endless range of flavorings; they may be natural, natural identical (chemically
synthesized imitations), or artificial (chemically unrelated to natural flavors). Emulsions are added to soft
drinks primarily to enhance "eye appeal" by serving as clouding agents. Emulsions are mixtures of liquids
that are generally incompatible. They consist of water-based elements, such as gums, pectin, and
preservatives; and oil-based liquids, such as flavors, colors, and weighing agents. Sapiens enhance the
foamy head of certain soft drinks, like cream soda and ginger beer.

To impede the growth of microorganisms and prevent deterioration, preservatives are added to soft
drinks. Anti-oxidants, such as BHA and ascorbic acid, maintain color and flavor. Beginning in the 1980s,
soft drink manufacturers opted for natural additives in response to increasing health concerns of the
public.

The Manufacturing Process of a Soft Drink

 Clarifying the water
The quality of water is crucial to the success of a soft
drink. Impurities, such as suspended particles,
organic matter, and bacteria, may degrade taste and
color. They are generally removed through the
traditional process of a series of coagulation,
filtration, and chlorination. Coagulation involves
mixing a gelatinous precipitate, or floc (ferric
sulphate or aluminum sulphate), into the water. The
floc absorbs suspended particles, making them
larger and more easily trapped by filters. During the clarification process, alkalinity must be adjusted
with an addition of lime to reach the desired pH level.

ANTKARACHI PLANT
 Filtering, sterilizing, and de-chlorinating the water
The clarified water is poured through a sand filter to remove fine particles of floc. The water passes
through a layer of sand and courser beds of gravel to capture the particles.

Sterilization is necessary to destroy bacteria and

organic compounds that might spoil the water's taste
or color. The water is pumped into a storage tank and
is dosed with a small amount of free chlorine. The
chlorinated water remains in the storage tank for
about two hours until the reaction is complete.

Next, an activated carbon filter de-chlorinates the

water and removes residual organic matter, much like
the sand filter. A vacuum pump de-aerates the water
before it passes into a dosing station.

 Mixing the ingredients

The dissolved sugar and flavor concentrates are pumped into the dosing station in a predetermined
sequence according to their compatibility. The ingredients are conveyed into batch tanks where they are
carefully mixed; too much agitation can cause unwanted aeration. The syrup may be sterilized while in
the tanks, using ultraviolet radiation or flash pasteurization, which involves quickly heating and cooling
the mixture. Fruit based syrups generally must be pasteurized. The water and syrup are carefully
combined by sophisticated machines, called proportions, which regulate the flow rates and ratios of the
liquids. The vessels are pressurized with carbon dioxide to prevent aeration of the mixture.

 Carbonating the beverage

Carbonation is generally added to the
finished product, though it may be mixed
into the water at an earlier stage. The
temperature of the liquid must be
carefully controlled since carbon dioxide
solubility increases as the liquid
temperature decreases. Many
carbonators are equipped with their own
cooling systems. The amount of carbon
dioxide pressure used depends on the
type of soft drink. For instance, fruit drinks require far less carbonation than mixer drinks, such as tonics,
which are meant to be diluted with other liquids. The beverage is slightly over-pressured with carbon
dioxide to facilitate the movement into storage tanks and ultimately to the filler machine.

 Filling of a Soft Drink

Soft Drinks are filled in Cans and Plastic (PET) Bottles. To do so Can Line Plant and PET Line Plant are
setup for the filling purpose.

CAN LINE
A can is made up of Aluminium Metal having a protective coating inside made up of polymer plastic
lining lacquer to prevent the contact of the beverage with the Aluminium, because if they contact each
other, then the corrosive nature of the beverage will eventually eat through the Aluminium and will
cause leakage in the can.

Alumnium is considered to be the best material for the soft drink cans than other metals, because: 

 It is easily formed and recycled

 It resists corrosion and will not rust
 It easily supports the carbonation pressure required to package soda and withstand pressures of
up to 90 pounds per square inch.

Mehran Bottlers provides 250ml of soft drink in their cans.

Working Steps of a Can Line Plant

1. A depalletizer unloads empty soft drink cans
from pallets onto a conveyor at an elevation
higher than the rest of the canning line.
2. The Cans are gravity fed through a twist
rinser, which rotates the can upside down
and rinses out the inside of the can, then
rotates the can back onto its proper upright
position at a lower elevation.
3. A Filler pours soft drink into the empty cans.
4. A Seamer applies lids to the full soft drink
can.
5. A can Inspection unit identifies cans that have
been under-filled and kicks them
off the canning conveyor.
6. The Cans flow through a rinse-
off tunnel to rinse beer overflow
off their exteriors.
7. The Cans flow through a blow-
off tunnel to blow moisture
droplets off their exteriors.
8. A Sleever or labeller applies labels to the cans.
9. A Can Coder prints a batch number or code onto the bottom of the cans.
10. Plastic Rings are applied to tops of the cans in 6 pack or 4 pack formations.
PROCESS FLOW DIAGRAM OF A CAN LINE
 PET LINE
In Beverage Industries, PET (Polyethylene terephthalate) are used in Plastic Bottles due these factors:

 PET is lightweight, due to which it is convenient for the transport.

 PET is Recyclable
 PET can be mold into different shapes and size, which enable brands to use them as an identity as
well as allows them to promote their drinks.

Mehran Bottlers provides 2.25 liter, 1 liter, 1.5 liter, 500ml, 345ml of soft drink in their PET Bottles.

Working Steps of a Pet Line Plant

Cleaning – Cleaning of the empty bottles is
probably the most important step in a PET line
plant. The reason is simple, a proper cleaning is the
only way to grant hygiene and safety.

Filling –This process is quite simple: the bottles are

grabbed by some grippers, while the above nozzles
pour the soft drink into them.

Capping – It is the final step performed by the

plant. The bottles are moved up to a capping
machine that provides each of them with a cap and seal
the soft drink into protected atmosphere. After the capping, drink is ready to be put on the market and
sold locally or on a higher scale.
 PROCESS FLOW DIAGRAM OF A PET LINE

Water Filling Process

 (12 STEPS TO PURITY)
We bring you Pakola Purified Drinking water after continuous inspection & quality assurance through
our 12 Steps to Purity.

Water Collection & Inspection

Water is collected from turbines after which it goes through thorough inspection and quality testing.

 Pre-Treatment
In this process, water is stored and is monitored on a daily basis.
The following are then performed:

 Chlorination of Raw Water: To disinfect and kill germs.

 GAC Multimida Filters: Through activated carbon filtration process we perform filtrations and de-
chlorination.
 Water Polishers: To remove sediment and physical contaminants to provide clean water.
 Reverse Osmosis Plant (Ro Plant)
The water goes through a treatment process that
effectively treats inorganic matter with the help of the
latest RO technology employing high pressure and semi
permeable membrane.

A reverse osmosis plant is a manufacturing plant where

the process of reverse osmosis takes place. Reverse
osmosis is a common process to purify or desalinate
contaminated water by forcing water through a
membrane. Water produced by reverse osmosis may be
used for a variety of purposes, including desalination,
wastewater treatment, concentration of contaminants, and
the reclamation of dissolved minerals. An average modern reverse osmosis plant needs six kilowatt-
hours of electricity to desalinate one cubic metre of water.  The process also results in an amount of
salty briny waste. The challenge for these
plants is to find ways to reduce energy
consumption, use sustainable energy
sources, improve the process of
desalination and to innovate in the area
of waste management to deal with the
waste. Self-contained water treatment
plants using reverse osmosis,
called reverse osmosis water Reverse
osmosis plants require a variety of pre-
treatment techniques including
softening, de-chlorination, and anti-
scalent treatment. Following pre-
treatment, high levels of pressure send water through a semi-permeable membrane, which retains all
contaminants but let pure water pass through. Energy requirements depend on the concentration of
salts and contaminants in the influent water; higher concentrations requires more energy to treat.

 Buffer Storage & Monitor

Water received in the buffer storage tanks are monitored on a daily basis.

 Post Treatment
The following are then performed

 Activated Carbon Filter: It is effective in the removal of

taste and odour from water and to treats chlorine,
pesticides, herbicides, and other dissolved gasses.
 Water Polishers: To remove sediment and physical
contaminants to provide clean water.


UV Light
Disinfection Unit: Kills or reduces the
presence of remaining microorganisms.

 Essential Mineral Dosing

Minerals are added as per water requirement and in accordance with consumer taste preferences.

 Ultra Filtration (0.2 Micron Filter)

It is effective in the removal of colloids, bacteria, pyrogens and other organic molecules larger than 0.1 –
0.2 micron size.

 Water Ozonation
The ozonation process ensures to kill microorganisms to make sure that our water is clear of harmful
bacteria.

 Filling & Capping Process

Water is then filled through positive pressure filling box, after which the capping process passes through
UV. This process is monitored and controlled throughout to ensure a controlled sanitary environment.

 Packaging Control
It is done with the help of physical human inspection and the latest equipment designed to ensure the
removal of any defects within packaging.

 Online Inspection & Quality Assurance

Our automated equipment ensures maximum quality control, cleanliness and effectiveness.

 Product Storage
Once all stages have been cleared, Pakola Purified Drinking Water is transported to the storage
warehouse, ready to be delivered to the end consumers.

CLEANING IN PLACE (CIP):

Clean-in-place is a method of automated cleaning the interior surfaces of pipes, vessels, equipment's,
filters and associated fittings, without major disassembly. CIP is commonly used for equipment such as
piping, tanks, and fillers. CIP employs turbulent
flow through piping, or spray balls for large
surfaces.

As a food, dairy, or beverage processor, you

understand the importance of maintaining a
hygienic process environment to ensure product
quality and purity. That’s where a good Clean-in-
place (CIP) System comes in.

CIP is a method of cleaning

 Sanitary process lines

 Vessels
 Equipment commonly used in process
plants

ADVANTAGES OF CIP
 Minimizes Mistakes: Automating cleaning reduces the chance of human error that can contribute
to an unsafe product.
 Keeps Employees Safe: Reduces chemical exposure by containing cleaning solutions within the
system.
 More Production Time: As less production time is lost to cleaning, more time is spent making
product.
 Product Quality: Reliable and repeatable cleaning means sustainable product quality and
consistency. Less contamination means fewer product recalls and higher brand confidence.
 Utility Savings: Water and energy usage is reduced through repeatable cycle control.
THE CIP CLEANING CYCLE:
CIP cycles are typically run either after a processing run that has produced normal soiling or when
changing over a processing line from one product to another.

Every CIP cleaning cycle has its own unique set

of parameters, so there’s really no such thing as
a “typical” CIP cycle. The elements, sequence,
and duration of the cleaning process can vary
widely from one system to another, but some
common steps are included in most cleaning
cycles

 STEP 1: PRE-RINSE
The pre-rinse is a very important step in the CIP process because a well-monitored and well-executed
pre-rinse makes the rest of the wash cycle predictable and repeatable.

The pre-rinse cycle:

 Wets the interior surface of the lines and

tanks
 Removes most of the remaining residue
 Dissolves sugars and partially melts fats
 Provides a non-chemical pressure test of
the CIP flow path

Use potable plant water, de-ionized water (DI),

water that has been processed through reverse
osmosis (RO), or re-use the final rinse solution
from the previous cleaning sequence. A
Turbidity Sensor may be used to verify that the
pre-rinse effectively removes all solids.

 STEP 2: CAUSTIC WASH (140° – 185° F)

Caustic washes soften fats, making them easier to remove. Also known as caustic soda, sodium
hydroxide or NaOH, the alkali used in caustic washes have a very high pH in a concentration range of
0.5-2.0%. Concentrations as high as 4% may be used for highly soiled surfaces.

Caustic is typically used as the main detergent in most CIP wash cycles. A non-foaming formulation can
help reduce pump cavitation and increase efficiency. It will also prevent tanks from overfilling with foam
when the system starts to recirculate.
Water Saving Tip: In many cases, the caustic wash can be returned to its tank and re-used multiple
times, which significantly reduces water, chemical, and energy costs over a single tank system.

 STEP 3: INTERMEDIATE RINSE

Fresh water flushes out residual traces of detergent remaining from the caustic wash. Use proper
instrumentation during each step of the CIP Cycle, including rinsing, ensures proper cleaning.

 Level Transmitters and Probes

monitor tank levels of wash and
rinse tanks.
 Flow Transmitters ensure optimum
flow for spray devices to precisely
control wash and rinse steps.
 Conductivity Transmitters ensure
chemical levels are hitting
predetermined set point.

 STEP 4: FINAL RINSE

Rinse with either DI, RO, or city water to
flush residual cleaning agents.

In many systems, the final rinse water may

be recovered and reused as the pre-rinse
solution for the next cleaning cycle. The
residual heat and chemicals it retains from
the final rinse will help make the next pre-
rinse more effective and economical.
 STEP 5. SANITIZING RINSE
May be required to help kill microorganisms before starting the next production run.

For many years, various hypochlorite solutions (potassium, sodium or calcium), also known as “hypo,”
have been used as sanitizers in many CIP cycles.

The active ingredient in a sanitizing rinse is chlorine (bleach), which is:

 Relatively inexpensive to use.

 Very effective as a sanitizing rinse for soils that are prone to bacterial growth such as dairy
products.
 Potentially harmful to stainless steel, causing staining, corrosion and pitting.

In recent years more sanitation managers have turned away from bleach-based sanitizers in favor of
peracetic acid (PAA) — a combination of hydrogen peroxide and acetic acid.

The PAA solution:

 It is a strong disinfectant even at low temperatures.

 Rinses away while leaving little or no chlorine residue to corrode stainless steel.
 Is effective against all microorganisms including spoilage organisms, pathogens and bacterial
spores.
 It has also proven to be more eco-friendly in the wastewater stream.
 Has a strong, pungent odor so it should only be used in well-ventilated areas.

Warning: Sanitizers reduce bacterial growth but don’t completely kill all pathogens in the system; since
it is the last step in the cleaning process, re-circulating the sanitizing solution could run the risk of
spreading any leftover contamination that might be present. Sanitizers can also be sensitive to high
temperatures and can lose their effectiveness fairly rapidly once they are in solution.

QUALITY CONTROL DEPARTMENT

The Quality Control Department is responsible of monitoring and ensuring that each stage of production
is followed by all the necessary procedures for safe use of machinery and that each product coming out
of the production process, complies with all standards and specifications that have been defined so to
ensure a smooth and trouble-free operation.

Quality Control for Soft Drink:

Soft drink manufacturers adhere to strict water quality standards for allowable dissolved solids,
alkalinity, chlorides, sulfates, iron, and aluminum. Not only is it in the interest of public health, but clean
water also facilitates the production process and maintains consistency in flavor, color, and body.
Microbiological and other testing occur regularly. The National Soft Drink Association and other agencies
set standards for regulating the quality of sugar and other ingredients. If soft drinks are produced with
low-quality sugar, particles in the beverage will spoil it, creating floc. To prevent such spoilage, sugar
must be carefully handled in dry, sanitized environments.

It is crucial for soft drink manufacturers to inspect raw materials before they are mixed with other
ingredients, because preservatives may not kill all bacteria. All tanks, pumps, and containers are
thoroughly sterilized and continuously monitored. Cans, made of aluminum alloy or tin-coated low-
carbon steel, are lacquered internally to seal the metal and prevent corrosion from contact with the
beverage. Soft drink manufacturers also recommend specific storage conditions to retailers to insure
that the beverages do not spoil. The shelf life of soft drinks is generally at least one year.

Equipment Used In the Quality Control Lab:

CARBO QC:
Carbo QC is the precise CO2 meter which allows reliable QC on
finished packages as well as highly accurate measurements in the
laboratory for product development. It gives you fast, accurate
and reliable determination of dissolved carbon dioxide in
beverages. When combined with Anton Paar’s PFD filling device,
sample is taken directly from the package into the measuring
chamber of Carbo QC - with no loss of dissolved carbon dioxide
during sample transfer. Carbo QC for the laboratory provides
reliable CO2 results, even out of very small packages.

SEPARATING FUNNEL:
Separatory funnels, or separation funnels, are a common fixture in chemistry labs. These funnels are
used to separate immiscible liquids from their solutes. The funnel is usually glass, pear-shaped, and
usually includes a stopper and a stopcock. In beverage industry it is used to remove carbon dioxide
from the sample using a suction pump.

MAGNETIC STIRRER:
A magnetic stirrer is a device used to create a rotating
magnetic field. The magnetic stirrer creates a rotating field
based on a rotating magnet bar or a plate containing the
rotating magnet. In general, the bar magnet is coated with
plastic and plate contains a rotating magnet. It is possible to create a rotating magnetic field with the
help of a rotating magnet.

SEAM CUTTER:
Seaming Cutting Saw is a specially designed saw for seam cutting
purpose. Equipped with linear guide rail, cans’ moving during
cutting will be very precise and accurate in track. Comparing to
typical seam saw, a clearer seam section will be obtained.

TORQUE METER:
It is used to measure the
torque of bottle cap.

TDS/EC/SALINITY METER:
A TDS meter is used to determine the amount of dissolved particles in the water, usually in parts-
per-million or ppm.

PH METER:
A pH meter is a precise instrument that weighs the
hydrogen-ion movement in water-based suspensions,
showing its acidity or alkalinity expressed as pH. It is also
called a “potentiometric pH meter” because it measures the variation in electrical potential between a
pH electrode and a reference electrode

BRIX METER:
Brix meters are devices used for an assortment of jobs
across many industries, but most notably in the food and
beverage industry. They provide a quick and accurate
measurement of Brix in almost any liquid sample

NOVA 60:
The Merck Spectro quant® NOVA 60 Photometer is an
instrument for the routine analysis of all water types and is
capable of measuring both the ready-to-use cell tests as
well as inexpensive reagent tests. All Spectro Quant® cell
and reagent tests can be measured with the NOVA 60.

Microbiology Tests
The safety of food and water is vital to our health. Food Testing helps manufacturers avoid releasing
tainted food or beverages to consumers. Harmful bacteria like E.Coli, salmonella, and listeria are all
tested for regularly by the FDA. Neglecting food safety standards can prove costly for food
manufacturers, restaurants, hotels and school cafeterias. Any business that sells food is subject to health
inspections and failing such an inspection has serious financial consequences.

Methods of Testing:
There are two ways we can perform microbiology testing

 Direct Method
 Membrane Filter Method
 For biological test, we will need Agar and Broth. Both of them are feed for bacteria, but has difference
in their appearance. Agar is in solid form, whereas Broth is in liquid form.

For Soft Drinks, Microbiological test for Yeast and Mold is performed.

For Water, Microbiological test for coliform bacteria is performed.

Coliform Colony Yeast and Mold Colony