KANDHARI BEVERAGES PVT. LTD.

NABIPUR

TRAINING REPORT
ON

COCA COLA BEVERAGES

SUBMITTED AS A PART OF B.TECH FOOD TECHNOLOGY

(8THSEMESTER)

FROM

BY
1.AMBIKA KUMARI BFT-13-07

2. SHABNAM AKHTAR BFT-13-12

3.SHAHNAZ ASHRAF BFT-13-29

4.ARWA SIRAJ BFT-13-77

______________________ __________________

HEAD OF THE DEPARTMENT FACTORY MANAGER

(COCA-COLA COMPANY) (COCA-COLA COMPANY)

DATE-------------------------- DATE---------------------
 Declaration by the students

I hereby declare this project report titled THE COCA COLA COMPANY submitted by us
is based on actual work carried out by us under the guidance and supervision of Mr.
JAGMOHAN SINGH and Ms. KOMAL SHARMA any reference to work done by any
other person or any institution or any other material obtained from other sources have

been duly cited.

DATE_____________

Name of the students Signature of the students

1. AMBIKA KUMARI

2. SHABNAM AKHTAR

3. SHAHNAZ ASHRAF

4. ARWA SIRAJ
 ACKNOWLEDGEMENT

We would like to express our gratitude and appreciation to all those who gave us the
possibility to complete this report. A special thanks to our final year Project Coordinator, Mr.
Aamir Hussain Dar,Professor,IUST, whose help, stimulating suggestions and encouragement,
helped us to coordinate our project.

We would also like to acknowledge with much appreciation , the crucial role of the staff of
Kandhari Beverages,Nabipur, who gave the permission to use all required machinery and the
necessary material to complete the internship.

A special thanks goes to the head of the project, Mr. Jagmohan Singh and Mr. Ashwani Saini
(Quality Managers), who have given their full effort in guiding us for achieving the goal as
well as their encouragement to maintain our process in track. Lastly, many thanks to Miss.
Komal Sharma for their kind help and cooperation throughout.

We have immense pleasure in successful completion of this work.

 INDEX

S.NO CONTENT

1. INTRODUCTION

2. WATER TREATMENT PLANT

3. SYRUP ROOM

4. RAW MATERIAL AND PACKAGING MATERIAL

5. PRODUCTS AND THEIR MANUFACTURING

6. MICROBIOLOGY LAB

7. SENSORY

8. EFFULENT TREATMENT PLANT

 INTRODUCTION

Coca Cola is one of the most recognized brands in the world. The original recipe for the
drink, which has been altered over the years, was created by John Pemberton at the eagle
Drug & Chemical Company in Columbus, GA.

The Coca-Cola Company, the world's leading soft drink maker, operates in more than 200
countries and sells 400 brands of alcoholic beverages. Coca-Cola is a globally recognised
successful company. The Coca-Cola was founded in May of 1886. As late as 1990's Coca-
Cola was one of the most respected companies in the world.The Coca-Cola Company and its
network of bottlers comprise the most sophisticated and pervasive production and distribution
system in the world.During the past 20 years, The Coca-Cola Company has kept ahead of
emerging trends by developing Quality, Environment and Occupational Safety & Health
requirements. These requirements are developed to exceed ISO 9001:2000, ISO 22000:2005
standards. As the Company grew globally, our standards evolved with it, but our management
system became too centralized and inflexible. Our operations needed the ability to locally
customize global requirements. In order to protect the trademark, we require a revolution in
our system to suit a changing world with changing expectations.
In response to the changing needs and expectations of users, customers and stakeholders, a
cross-functional and cross-geographical team developed a framework and management
system model to replace our previous model known as The Coca-Cola Management System
(TCCMS). With KORE as our new governance framework and management system. KORE
enforces requirements not only to protect our products, but also to ensure the safety and well-
being of our associates and partners and to be environmentally responsible.
 KANDHARI BEVERAGES PVT. LTD.

(A Franchise of Coca-Cola Company)

Kandhari beverages Pvt. Ltd. was established in 1967 by Mr. Teja Singh Kandhari,is
presently a progressive business house in India. The group's first venture was a bottling unit
as a franchisee of PARLE's soft drink manufacturing "Gold Spot" , under license from Parle
established at Amritsar in the North Indian state of Punjab. The company is engaged in the
business of manufacturing, marketing and distribution of aerated water under franchise
agreement with the Coca-Cola Company,USA. The company has three mega green field
bottling plants for filling soft drinks located at village Nabipur, District Fatehgarh
Sahib(Punjab), Saha, District Ambala(Punjab), village Kattha,Baddi, District Solan (HP).
Present gross turn over of the company is approximately Rupees 190 Crores.The company
has also entered the power sector by setting a 6.25MW wind mill project having 5 units in the
state of Maharashtra.

In 1993, the world's renowned soft drink giant Coca-Cola entered India and brought over
PARLE brand of soft drink products. Being one of the star bottlers of PARLE, the group
switched to manufacturing bottling and marketing of Coke brand of soft drink products.The
group comapanies are conscious of their socio-economic responsibilities and have taken up a
series of community development programmes especially the funding setting up the
reinforest project to conserve scarce natural resources.There are four lines established in the
plant. Line 1 is a new setup plant started last year and manufactures CSD. It is the only plant
produces 750 bottles per minute.Line 2 is HOTFILL . Line 3 is CSD and Line 4 is TETRA-
PACK.
 ABOUT COCA COLA

LOGO

The famous COCA COLA logo was created "JOHN PEMBERPON'S bookkeeper,FRANK
MASON ROBINSON in 1885.The writing style used, known as Spencerian script, was
developed in the mid-19th century.

Confederate Colonel JOHN PEMBERTON, who was wounded in the American Civil War
and became addicted to morphine, began a quest to find a substitute for the problematic drug.
The prototype Coca cola recipe was formulated at Pemberton's Eagle Drug and Chemical
House, a drugstore in Columbus, Georgia, originally as a coca wine.He may have been
inspired by the formidable success of Vin Mariani, a French coca wine.

Coca-Cola (often referred to simply as Coke) is a carbonate drink produced by The Coca-
Cola Company.The drink's name refers to two of its original ingredients, which were kola
nuts (a source of caffeine) and coca leaves. The current formula of coca cola remains a trade
secret, although a variety of reported recipes and experimental recreations have been
published.

The Coca-Cola Company produces concentrate, which is then sold to licensed Coca-Cola
bottlers throughout the world.

The Coca-Cola Company has on occasion introduced other cola drinks under the Coke name.
The most common of these is Diet Coke, along with others including Caffeine-Free Coca-
Cola, Diet Coke Caffeine-Free, Coca-Cola Cherry, Coca-Cola Zero, Coca-Cola Vanilla, and
special versions with lemon, lime, and coffee. Based on Interbrand's "best global brand"
study of 2015, Coca-Cola was the world's third most valuable brand.In 2013, Coke products
were sold in over 200 countries worldwide, with consumers downing more than 1.8 billion
company beverage servings each day.
COCA COLA was the leading soft drink brand in India until 1977 when it left rather than
reveals its formula to the goverment reduces its equity stake as required under the foreign
exchange regulation act (FERA) which governed the operations of foreign companies in
India.

After the 16-years absence,COCA COLA returned to India in 1993, cementing its presence
with a deal that gave coca cola ownership of the nation soft drink brands and bottling
network.

The COCA COLA company is a global company with some of the worlds most widely
brands, the coca cola business in India, as in each country where it operates, is a local
business. Popular Indian brands including Thums up (the most trusted brand in
India),Limca,Maaza,Citra and Gold.Spot provided not only physical manufacturing,bottling
and distribution assests but also strong consumer preference.Leading Indian brands joined
companies international family of brands, including coca-cola,diet coke,sprite and fanta.

In 2000,the company launched the Kinley water brand.

Ingredients
 Water

 Sugar (sucrose or high-fructose corn syrup(HFCS) depending on country of origin)

 Concentrate

 Carbon dioxide

 Pulp
 WATER TREATMENT PLANT:-

In Kandhari beverages plant, Nabipur there are two plants for water treatment. In water
treatment plant-1 Two borewells are the source of water.River water,surface water and
ground (running) water are approved by coca cola. The sanitization is done after every 15
days and the chlorination is done after 2 hours at 80ppm.Raw water storage tank comprises of
3 collection tanks and 1 recovery tank .In collection tank range of chlorine added is 3-
5ppm.The water then is passed to the coagulation tanks which has the capacity of 50,000 ltrs
where chemicals like Lime,calcium chloride,calcium hypochlorite and ferrous sulphate are
added.

Firstly,Lime is added in an amount of 21.500kg which increases the pH and breaks down the
bicarbonate componds into carbonate compounds.The alkalinity and hardness decreases.
Then calcium hypochlorite is added around 700grams which stops or kills the microbial
growth and removes pesticides and increases the pH.Calcium choloride is then added where
the heavy particles like zinc reacts with calcium chloride and is removed.It helps in making
the bonds of organic componds and is added in the quantity of 4.0 kg.Ferrous sulphate is then
added which helps in settling downn of heavy particles and maintain the iron value and
floculation.Ferrous sulphate is approximately added 3.0kg.

After 10 minute interval these chemicals are mixed. A contact time of 35-45 minutes is given
and agitators are stopped.

After filling and settling for 4 hours testing of processed water is done. Testing like
alkalinity, P-value, M-value,Chloride ,total hardness and pH is done. After coagulation tank
water then passes to the sand filters where chlorination is monthly done at 50 ppm to remove
microbial growth,at a contact time of 4 hours. Again testing is done to check alkalinity,
chloride(3.5), pH, total hardened and turbidity (<0.3NTU). After sand filters the water is then
purified in carbon filters. For cleaning, steaming is done at 85-90degree celcius monthly at a
contact time of 2 hours. Chloride and turbidity is checked where chloride should be nil and
turbidity <0.3NTU. Then the water is passed to activated carbon filters(ACF) where 2200 kg
carbon is added, water passes through lead and lag ACF's (LLACF). Steaming at 85-90
degree celcius is done for cleaning after every 3 months and backwashing after every 24
hour. It then passes through the 10 micron filter where physical particles of size 10 micron or
more are absorbed. Through 5 micron filter, the particle having size 5 micron or more are
absorbed. It then passes through the UV tube system for disinfection. Then water is passed
through 1 micron filter where particles of size 1 micron or more are absorbed. And then water
is allowed to the syrup manufacturing and proportioning. The water is used for CIP, syrup
preparation and filling. After 1 micron water is tested for alkalinity,AOT, pH, TH,
chloride,sulphate,iron,TDS and chlorine.

WATER TREATMENT FOR SOFT WATER:-

The raw water and recovery water in step one, chlorinated around 3-5ppm is passed to the
sand filter( backwashing done weekly and the backwashed water is drained to ETP and
recovery) where heavy particles are retained on the basis of turbidity. It is then passed to
softener which reacts with Sodium Chloride and reduces the hardness. This water is then
transferred to the cooling tower, boiler and to the rinser and soft water storage tank(1-3
residual chlorine) [ At this step there is a chance of OPRP].

RINSE RECOVERY WATER TREATMENT:-

The backwashed water from WTP-1 is recovered in recovery pit-1 and the rinse water from
pet rinser and backwashing of WTP-2 is collected in recovery pit-2. The recovery pit is
chlorinated at 3-5ppm and then the water is transferred where chlorine dosing is done to
maintain the chlorine of 3-5 ppm. In case of overflow the water is then transferred to
intermediate tank at 50ppm for 4 hours. It is then passed through the sand filter(backwashed
water drained to ETP). Then the water is passed to the recovery storage tank(3-5ppm) and
can be used for domestic use.

In WTP-2 only treated water is processed and the difference between the two plants is that
WTP-2 has 5 coagulation tanks while WTP-1 has 6 coagulation tanks.
 FLOW CHART FOR WTP:-

BORE WELL 1 AND 2

3 COLLECTION TANKS 1 RECOVERY TANK

CHLORINATION DONE 3-5 PPM

COAGULATION TANK

ADDITION OF CHEMICALS:-

LIME

CALCIUM CHLORIDE

CALCIUM HYPOCHLORITE

FERROUS SULPHATE

CHLORINATION= 3-5 PPM SETTLING TIME = 4 HOURS

SAND FILTEER

CHECK CHLOORINE=3-5 PPM REMOVES PHYSICAL PARTICLES

ACTIVATED CARBON FILTER

REMOVES PESTICIDES

10 MICRON FILTER
CHLORINE= NIL

5 MICRON FILTER
WAVELENGTH= 150nm

UV TUBE DISINFECION OF WATER

1 MICRON FILTER WATER SEND FOR

PROCESS USE
FLOW CHART FOR SOFT WATER TREAMENT:-

RAW WAER STORAGE

TANK

ADD CHLORINE =3- 5 PPM

SAND FILTER

CARBON PURIFIER

(NaCl) SOFTENER

COOLING TOWER AND

BOILER

SOFT WATER SORAGE TANK

ADD CHLORINE = 1-3 PPM

RINSER AND WARMER

 TESTING OF WATER

 ALKALINITY:- Take 100 ml sample in a sample rinsed conical flask. Add 2-3 drops
of phenolpthaline indicator(pH=8.2-9.8).Pink colour appears. Titrate it with sulphuric
acid (N/50) untill pink colour disappears. Note the reading of the burette; this reading
gives the P-value. Now add 2 drops of methyl purple which gives it a greenish
colour and titrate it again until green colour turns bluish. Again note the reading of the
burette; this reading gives the M-value.

 TOTAL HARDNESS:-Take 100ml sample and add 1 crushed tablet of total hardness
to it (pink colour).Then add ammonia buffer solution(2-3 drops) using pipette.Then
titrate it with EDTA solution(N/50) until pink colour changes to blue.

 CALCIUM HARDNESS:-Take 100 ml sample and add 1 crushed tablet of calcium

hardness (rosy pink colour). Then add 2-3 drops of Sodium Hydroxide using pipette
(slightly dark pink colour). Titrate it with EDTA (N/50) until pink changes to dark
pink.

 pH and TDS :- pH of water is checked using a pH meter or Density meter where its
probe is dipped into the sample of water in the beaker and the meter shows the
reading when it gets stable. Now dip the TDS probe in water sample and note the
reading when it gets stable.
 CHLORINE:-Take 25ml sample and add reagent of total chlorine[to check free
chlorine use 1 pouch if DPD-1 and to check total chlorine use 1 pouch of DPD-4].
Mix and shake it properly. Now take a blank sample of water in one tube and reagent
sample in another tube of Hach test kit. Place the blank sample tube on the left side of
the Hach kit and reagent on the right side. And match the colour.

 TURBIDITY:- Turbidity is checked by Turbidity meter (weekly calibration done).

Take 25 ml sample in the probe and dry it off from outside with the tissue. The water
sample must be deep enough to cover the tip of electrode. The probe sensitivity is
effected by temperature of the water; so the reading of meter cannot be accurate. wait
for the meter to come to the equilibrium. The meter has reached equilibrium when
measurement becomes steady.
 OPRP (OPERATIONAL PRE- REQUISTING PROGRAM):

A prerequisite program identified by the hazard analysis as essential in order to control the
likelihood of introducing food safety hazards to and/or the contamination or proliferation of
food safety hazards in the product(s) or in the processing environment.

Total parameters:

RAW WATER TREATED WATER

TOTAL HARDNESS MAX. 500 MG/L <100MG/L

TOTAL ALKALINITY MAX 100 MG/L <85MG/L

CHLORINE 3-5PPM NIL

TURBIDITY MAX 0.5 NTU <0.3NTU

SULPHATE 400MG/L 250 MG/L

CHLORIDE 1000 MG/L 250 MG/L

SENSORY(A/O/T) NORMAL NORMAL

pH 6.5-8.5 7
 THE SYRUP ROOM

The purpose of syrup manufacturing is to provide operating guidelines for in-plant treatment
of non-refined granular sugar using powdered activated carbon.The purpose for treating non-
refine granular sugar using hot powder activated carbon that will ensure the availability of
sugar or simple syrup which meets the specifications of coca cola company.The activated
carbon process utilizes its adsorption properties to remove colour and odour causing
components from a sugar syrup solution.Four factors influencing the effectiveness of
activated carbon treatment :

1. Surface Area(quality and quantity of activated carbon)

2. Contact Time

3. Agitation

4. Temperature

This process should be used for treating sugars with a colour less than 35 ICUMSA
units.Powdered activated carbon can also be used for removing low levels of organic
residues,such as pesticides which might be present in the sugar.

SYRUP TANKS

Simple and final syrup tanks, agitators, metal fittings must be stainless steel type 304 or 316
with number 2B or better finish.Dome-top design containing no pockets, sacks or joints
which prevent free and complete drainage.Fitted with clean-in-place facility.

PRE-COAT TANK

A small stainless steel tank,with agitator or circulation pumps,is needed to assist in

precoating the filter press.The capacity should be approximately two to three times the
volume needed to fill the filter press and associated pipe work.

SYRUP PUMPS

All pumps used to handle syrups must be easily cleanable and sanitizable.Sanitary stainless
steel pumps,approved for use food products, must be used.Bronze pumps and pumps with
rubber impellars must not be used.
STRAINERS

Strainers must be stainless steel(type 304 or 316) and shall be easily removable.Strainers of
30 to 40 mesh must be used for in-line filteratrion of simple syrup.

SYRUP FILTERS

The filter press must be constructed of type 304 or 316 stainless steel,and must be capable of
withstanding hot (85 degree celcius) sanitation .The filter press should be large enough to
filter the largest expected batch of simple syrup in one continuous operation.

Vertical Plate and Frame Filters

The Vertical plate filter is the most widely used and its commonly referred to as a "Plate and
Frame "filter. The plates are constructed of screened or perforated

grids used to support the filter paper only,and do no filtering. Frames or hollow boxes are
inserted between the plates as spacers to allow passage of the incoming liquid and the space
for the filter cake to build up on the filter paper.
 Simple Syrup Manufacturing
Three stainless steel tanks are needed:a mixing tank, a pre-coat tank, and a filtered simple
syrup tank.A filtered press is needed to filter the mixture and filter-aid is needed.The sugar
bags are stored in the dumping room , from where its transferred to raw syrup tank by
vaccum conveyors. Sugar gets dissolved in the already filled tank.Syrup manufacture requires
treated water of the same quality as that used for finished beverages. Water may be added by
volume or by weight.Treated water is heated by the steam coming from boiler(65degree
celcius).The Jet Mixer mixes the solution and sugar gets dissolved.Temperature of the tank is
raised when sugar no more dissolves further (saturation point) and reaches upto 85 degree
celcius where resting time is given for half an hour.
In Pre-Coat tank, Activated Carbon (0.3%) is added and then dicamex hyflow (0.225%) is
added where Carbon acts to improve colour and Dicamex supports filteration process.From
Pre-coat tank, Activated carbon and Dicamex are transferred to raw syrup tank
simultaneously where again half an hour resting time is given (OPRP).Meanwhile, Dicamex
solution (prepared in treated water) is passed through filter press for pre coating of dicamex
over filter paper.

The precoating of filter press increases the surface area and porosity i.e., overall capacity of
filteration process is increased.The raw syrup is passed through filter press,the inlet pressure
should be 3.5 kg and outlet pressure about 0.11kg. The required pore size of the filter paper is
equal to 10-15 micron ,whose usage time is one hour and twenty minutes and the volume
which is passed through is 26KL. Sample is taken after every 10 minutes and filtered on
white paper where in some case black particles are retained on the filter paper. This syrup is
circulated from raw syrup tank to the filter press to again raw syrup tank for about 25-30
minutes until solution runs clear.Then,this syrup is passed through PHE(PLATE HEAT
EXCHANGER) to reduce temperature upto 25-30 degree celcius.The syrup is passed
through treated water, chilled water and cooling tower. The treated water used in PHE is
stored in recovery tank for further use in syrup making as the temperature is already around
30 degree celcius,so little amount of energy is used to increase temperature and further upto
65 degree celcius for dissolving sugar.The raw syrup can be used upto 60 hours after
mixing.This clear syrup is transferred to ready syrup tank where concentrate is added and
brix is checked and after half an hour resting time ,its transferred to different lines.Simple
syrup shall be used in the manufacturing of final syrup as soon as possible and must not be
stored beyond 24 hours in any condition.
FLOW CHART OF SYRUP:-

SUGAR DUMPING

RAW SYRUP TANK

TEMP.= 85DEGREE CELCIUS

ADD ACTIVATED CARBON

AND DICAMEX
SEPARATELY

½ HOUR CONTACT TIME

PASS THROUGH FILTER

PRESS COATED WITH
DICAMEX

SYRUP IS PASSED THROUGH

PLAE HEAT EXCHANGER

PREPARED SYRUP IS
TRANSFERRED TO READY
SYRUP TANK
SYRUP TESTS:

ICUMSA

1.SIMPLE SYRUP COLOR

Procedure

 Collect the sample of simple syrup after re-circulation in the filter press in a clean
beaker (100ml capacity) and cool it gradually in a water bath.

 Dilute the syrup to 50degree Brix the table.

 Adjust the PH of 5degree Brix syrup to by using NAOH or 0.1N HCl.

 Filter the sample solution under vaccum through a membrane fiter (0.45 micron) into
a clean dry conical flask.

 Deaerate the filter solution for though at room temperature in a vaccum oven or an
evacuated desicators . Alternating degree by immersing the conical flask containing
the sugar solution , in an ultrasonic bath for 3 minutes.

 Set the spectophotometer wavelength to 420mm.

 Rinse the measuring cell with sugar solution and then fill with the sugar solution.

 Determine the absorption of solution using filtered distilled water solution using
filtered distilled water as a reference standard for zero color.

Calculation:

ICUMSA color=

Absorbance x1000/ cell length (in cm) x concentration

Recalculate the sample syrup until ICUMSA color <35.

TASTE AND COLOR OF SYRUP

Procedure For Simple Syrup

 Collect the sample of the simple syrup .

 Dilute the sample in 1:5 ratio with water.

 Pour the sample in taste glass, then smell, and taste the product.

Procedure For Final Syrup

 Collect the sample of final syrup after proper mixing.

 Dilute it with titrated water to the ratio as per the flavour- mixing ratio.

 Pour the sample in the taste glass, then smell, and taste the product.

SYRUP APPERANCE

Procedure

 Collect 50ml sample and 250ml distilled water.

 Assembled filteration unit by placing 0.45micron filter paper in it.

 Attach the filteration unit by vaccum pump.

 Pour sample into unit and switch on vaccum .

 After entire syrup passes through the filter paper, switch off vaccum and retrieve
filter paper .

 Observe under magnifying glass for presence of carbon particles.

FLOC TEST
 Prepare 1 filter of 54 brix solution and acidify the solution to ph 1.5 using 2N
phosphoric acid.
 Cover the container and let it stand for ten days at room temperature.
 Shine a high intensity light on the sample to absorb any kind of floc.
RAW MATERIAL OR PACKAGING MATERIAL OR IPQP
(IN PLANT QUALITY PLANT)
RM/PM has the requirement from coca cola called as KORE (coca cola operating
requirements).We have to follow the given guidelines for the acceptance of material.

1.Packaging Types - Primary, Secondary and Tertiary

 Primary packaging is the material that first envelops the product and holds it. This
usually is the smallest unit of distribution or use and is the package which is in direct
contact with the contents like preforms and closures.

 IPQP- PET PREFORM

PURPOSE:- To ensure that the incoming preform are inspected and accepted as per agreed
plan before being released for use or rejected when received at the bottling plant.

SCOPE:-It is executed on the preforms supplied by the authorized to the bottling plants.

For correct decisions, carry out incoming inspection at the time of unloading with 1 week of
receipt of material.

Preform tests:-

In Preform ,following tests are done:

1. weighing of preform

2. visual color

3. Diameter:- is checked by vernier callipers.

4. Length.
5. Thickness.

6. Perpendicularity test:- It is done by perpendicularity tester. Preform is placed on the

mandle (preform holder)and then the meter tip is bought just in contact with the preform
fixing the meter immovable. Then tare the meter by pressing zero. Rotate the mandle and
check the perpendicularity. The reading should be <0.5 for all preforms.

 IPQP - PLASTIC CLOSURES

PURPOSE:- To ensure that the incoming closures are inspected and accepted as per agreed
plan before being released for use or rejected when received at the bottling plant.

SCOPE:- It is executed on the closures supplied by the authorized to the bottling plants.

For correct decisions, carry out incoming inspection at the time of unloading with 1 week of
receipt of material.

Secondary and Tertiary packaging :-Secondary packaging is outside the primary packaging
- perhaps used to group primary packages together while as Tertiary packaging is used for
bulk handling warehouse storage and transport shipping. The normal form is a unit load that
packs tightly into containers like shrink wrap,stretch wrap,labels, corrigated box,TTP
laminate.
TESTS:-
1. Shrink wrap:-

 GSM( gram square meter):-Take shrink wrap samples of different width x length of
530 x 60 & 530 x 70.Take a standard GSM cutter (10 x 10) 7 trace it out on both
wraps.Cut the traces and weigh them on weighing balance.

 Thickness:-It is checked by digital screw gauge .Place in screw gauge ,the sample, at
different places and check its thickness.

2.Label:-The measurements of the label are measured using a measuring scale(length x

breadth)in millimeters.

 Thickness:-It is checked by digital screw gauge .Place in screw gauge ,the sample, at
different places and check its thickness.
2.INCOMING RAW MATERIAL:-
1.Carbon Dioxide
 T/O/A(Taste/Odour/Appearance)

 Purity Test

 Snow Test

 Odour after Acidification(taste in water)

TO CHECK THE PURITY OF CARBON-DIOXIDE GAS BY PURITY

TESTER(ZAHM NAIGEL):
Zahm Naigel flask is used to check purity of CO2.Base of 30% W/V is used either
KOH/NAOH.

PROCEDURE:
1.Take sample from tanker to the flask.

2.Open the cork of flask and allow to flow CO2 for 7-10 minutes.

3.Close the cork.

4.Pour 30%of NAOH base in flask.

5.Small bubbles will form after some time.

6.Tilt the flask in vertical direction and note the reading on scale.

7. 99.9% is purity specification given by KORE and 99.99% is the highest purity level.
TO CHECK THE TASTE AND ODOUR OF CARBON-DIOXIDE GAS:-
1.Take 400ml of water in a beaker.

2.Add 20gm of sucrose to it.

3.Mix it properly on magnetic stirrer.

4.Add 15ml citric acid to it.

5.Mix it properly and refrigerate it for sometime.

6.Pass carbon-dioxide gas through above prepared sucrose solution for 15 minutes.

7.Smell and taste the solution after that.

8.There should be no off odour and off taste.

2. SUGAR
 T/O/A(Taste/Odour/Appearance)

 Odour after Acidification

 Floc

 Colour

3. CHEMICALS
 Ferrous sulphate

 Lime

 Calcium hypochlorite

 Salt

 Sodium hydroxide

4. PULP
 Visual

 Sensory

 Food grade
3. PROCESSING AID: A processing aid is a substance used in the production of processed
food, and which may end up in the finished product.

 PAC(Powdered Activated Carbon)

 FLOW AID

1. Hyflow

2. Dicamex and Decalite

 FILTER SHEET

 WTP CHEMICALS

4. AUXILLARY MATERIAL:
 Glue for label

 Date Code Ink

 Lubricants on Conveyor

 Boiler Chemicals
 PRODUCTS AND THEIR MANUFACTURING
CARBONATED SOFT DRINKS(CSD)PRODUCTS:
 COCA-COLA

 LIMCA

 SPRITE

 THUMS-UP

 FANTA-ORANGE

 RIMZIM

 KINLEY SODA

 DIET COKE

 COKE ZERO
 HOT FILL AND TETRA PACK PRODUCTS:-
 Maaza

 Minute Maid

LITCHI

APPLE

ORANGE

GUAVA

MIXED FRUIT
 CSD MANUFACTURING:
The preforms are transferred from the dumping area to the production line through conveyor.
The impurities are removed by ionisation process, from where preform enters heating section
where softening temperature around 98-110 degree celcius,usually 106 degree celcius is
given. The machine then passes the preforms to the blowing wheel where air blow moulding
occurs.In blowing wheel heated preform undergoes stretching, pre-blowing (at 8.2 bar),final
blowing (at 28 bars) an snifting where pressure inside the bottle is released. But the base of
the formed bottle still has high temperature so base cooling is done by injecting chilled water
(8-10 degree celcius) at the base. Meanwhile, ready syrup is transferred through the pipes to
the tank in production line where Carbon Dioxide is mixed with it at 20 degree celcius.This
mixture is then transferred to the filler for filling in bottles. Also, bottle goes for labelling and
then filling is done by counter pressure mechanism. Once filled, bottles are then capped.
Closures reach the filling section through the conveyor which ensures each cap stays scratch
free and is in the right position to be precisely placed on the bottle. If closure is defected then
the bottle won't be able to hold the desired carbon dioxide content in it. The bottle is now
ready to be coded by a laser printer. Each bottle is marked with a special code which
identifies different batches. It identifies the date, batch number, time, lot number and the
MRP. The company inspects the bottles at many points during the process. Also, level of the
beverage filled is checked by a sensor. If level exceeds or is below the desired level, it gets
rejected automatically. Then bottles are conveyed further for shrink wrapping, palletising,
loaded to crates and then stored.
 CSD PRODUCTS:
THUMS UP
Thums Up is a brand of cola in India.The logo is a red thumbs up. It was introduced in 1977
and was acquired by the Coca Cola Company in 1993.Thums up is a leading carbonated soft
drink and most trusted brand in India.Thums up is known for its strong, fizzy taste .

FANTA
The 'Orange' drink of the Coca Cola company,is one of the favourite drinks since
1940's.Fanta entered the Indian market in the year 1993.Over the years Fanta has occupied a
strong market place.Fanta has an vibranrt colour, tempting taste and is associated with
cheerful and special times with family and friends.
LIMCA
Limca is a lemon and lime flavoured carbonated soft drink made primarily in India and
certain parts of the U.S. It contains 60 calories per 150ml can.Limca brand was introduced in
1977.Limca has been the original thirst choice of millions of consumers.Limca energizes and
refreshes.

SPRITE
Sprite is ranked worldwide as the number 4th softdrink and is sold in more than 190
countries.In India,sprite was launched in the year 1999.Today it has grown to be the fastest
growing soft drink.Sprite is a colorless, caffeine-free, lemon and lime-flavoured soft drink
created by The Coca-Cola Company.Bottles of Sprite are usually a transparent green colour
with a green and yellow label whereas cans are coloured silver, green, blue and aluminum
bottles are colored a solid lime green.
COCA COLA
Coca Cola is a carbonated soft drink produced by the Coca Cola company.It is a leading soft
drink brand in India.The drinks name refers to,two of its original ingredients which was cola
nuts(a source of caffeine)and coca leaves.
 FLOWCHART FOR CSD MANUFACTURING:-

PREFORM READY SYRUP+ WAER

HEATING AT 98-110 DEGREE

DISSOLVING OF CARBON
CELICIUS
DIOXIDE AT 25 DEGREE
CELICIUS

AIR BLOW MOULDING

LABELING OF BOTTLES

FILLER

CAPPING
 SHRINK
WRAPPING

LOADED TO CRATES

STRETCH
WRAPPING

WAREHOUSE
 TESTING OF CSD FINISHED PRODUCTS:
1.DROP TEST:-The bottle is dropped from a height to check if the bottle is strong enough to
bear the dropping pressure.

2.GAS VOLUME TEST:- Dip the temperature probe just inside the bottle to remove the
excess gas in the head space and tighten the knob,then shake the bottle until pressure
becomes constant.Then take out temperature probe from the bottle and dip the thermometer
inside the bottle to check the temperature of the bottle. Gas volume reduces if the temperature
is high.

3.DEGREE BRIX:- Using density meter ,inject the distilled water to clean it and then inject
the sample and press start for checking the reading. At a temperature of 20 degree celcius,the
readings are shown on the density meter.Take sample 100ml and shake the flask to de-gas the
sample and then inject into the density meter to check the brix. If gas is not removed ,the tube
inside the density meter measures the moving particles and gives the sugar content.But if the
gas is present in the product , the tube will measure the air bubbles and the reading shown
would be incorrect.

4.TORQUE TEST:-The Torque test is done to know the force required to open the closure
.It ranges from 11±6.Torque is the force applied at 90 degree.

5.STRESS CRACK:-Caustic soda of 0.2% solution is made and base of the bottle is dipped
in it for 20 minutes to check whether bottle base cracks or not.

6.BOTTLE CUTTING:- It is done by bottle cutting machine. An empty bottle is placed in

bottle wire cutter which cuts it into three parts- neck, base and body. And weight of each part
is checked.
 HOT-FILL MANUFACTURING

MAAZA AND MINUTE MAID PRODUCTS:-

The plant comprises of one simple syrup tank,two ready beverage tanks and two blending
tanks.The syrup, concentrate ,flavours as per sequence are taken in blending tank where
mixing of all flavours, concentrate, emulsifiers and stabilizers are done. The pulp are of two
types totapuri(306 Kg/unit) and alphanzo(54kg/unit). Volume makeup is done by adding
water to the pulp and then brix is checked. The standard brix is 15.17.

Total amount of water = Actual Brix - Standard Brix x 2541 (water factor) x number of units
/Actual Brix.
Then again water is added and final brix is checked.Here testings are:-
 Brix

 Titrable Acidity

 pH

 Viscosity

 TOA

 Foreign Matter

 Acidity

 Particle Size

It is then passed to the homogeniser( to reduce to small particles of uniform size and
distribute evenly, usually in a liquid), where pressure is 2500-3000 psi. It is then transferred
to the ready beverage tank where particle size testing is done (<3 microns). The juice is then
passed to the pasteurizer where partial sterlization of a substance especially a liquid at a
temperature 84-88 degree celcius and for a period of exposure that destroys the
microorganisms. It then passes to the filler where filling is done at 82 degree celcius. The
bottles are passed through the conveyor. The tilt conveyor tilts the bottle and brings the
pasteurised juice in contact with the closure so as to kill the micro organisms present. It is
then passed to the warmer containing 6 sections of different temperatures ( 65ºcelcius, 55
ºcelcius, 45ºcelcius, 35º celcius , 30ºcelcius) and the juice comes out of the warmer with
temperature around 20 ºcelcius. Then the labelling is done by the sleever, date coding is done
and then a sensor light inspects the level of the juice. Then shrink wrapping is done by SMI
and palletization is done and then the palletized juice bottles are stored in the wearhouse.CIP
of these tanks is done in 5 or 7 steps.CIP is done in steps and on every step there is different
temperature and time.The five steps are rinsing with treated water(10 minutes),caustic
soda(1-2%for 15 minutes 65-70ºcelcius,rinsing with treated water(10minutes),hot water(15
minutes),rinsing(10 minutes).

The seven steps comprises rinsing with treated water(10 minutes),caustic soda(1.5%,65
ºcelcius for 15 minutes),rinsing (10 minutes),phosphoric acid (1-2%,70ºcelcius for 15
minutes),rinsing (10 minutes),hot water (85ºcelcius),rinsing(10 minutes).
FLOW CHART FOR HOT FILL:-
BLENDING OF PULP+
READY SYRUP +COLOUR +
PECTIN(ONLY FOR
APPLE,ORANGE,LITCHI)

READY BEVERAGE TANK

CHECK FINAL BRIX

PASTEURISER TEMP. 96—98

DEGREE CELCIUS FOR 5-10
SECONDS)

FILLER (84-88 DEGREE

CELCIUS)

TILT CONVEYOR

COOLING TUNNEL

SLEEVER

DATE CODING

LIGHT INSPECTION

SHRINK WRAP MACHINE

PALLETISER AND STRETCH

WRAPPING

WAREHOUSE
 TESTING OF JUICE
1. Viscosity:- Viscosity is checked by a viscometer. Viscometer contains a spindle and a
temperature probe (which ensures 20 degree celcius temperature). Take 500ml sample at 20
degree celcius in a beaker. Lower the meter so that spindle dips completely into the juice
beaker.Spindle rotates at 60 rpm and the digital meter above gives the reading. Viscosity of
the juice should be more than 30. Viscosity liquids are used for calibration of viscometer.
Standard solutions of 48.8 centi-poise, 9.6 centi-poise, and 96.7 centi-poise at 25 degree
celcius are used for calibration.

2. Particle Size:-Take 2 drops of sample on a slide and place a cover slip over it such that no
air bubble is trapped inside. Using water rinse the stage on which slide is to be placed.Place
the slide under the eye piece and focus the microscope. Particle size should be < 3 microns.
The lens containing the scale can be rotated to check the particle size.

3. Titration:- Take the sample in a titration flask and add 2-3 drops of phenolpthaline
indicator. Titrate it with 0.1N Sodium Hydroxide and note down the reading.

4. pH:- Can be checked either by pH meter or by the formula.

pH=burette reading(net) x N of NaOH x Acid Factor / weight of samplex8.20 pH should be

maintained.

5. To check the ⁰BRIX:-

Firstly clean the refractometer with distilled water.Zero base the refractometer with distilled
water.Put drop of sample on the detector.Note down the reading .

6. NET CONTENT:-

Net content=Gross Wt-Empty bottle wt/apparent density

7. TORQUE:-The Torque test is done to know the force required to open the closure .It
ranges from 11±6.Torque is the force applied at 90 degree angle.

8. BOTTLE CUTTING:- It is done by bottle cutting machine. An empty bottle is placed in

bottle wire cutter which cuts it into three parts- neck, base and body. And weight of each part
is checked.
 TETRA PACK MANUFACTURING:-

Tetra Pack is currently the largest food packaging company in the world by sales, operating
in more than 170 countries and with over 23,000 employees (2012). In this plant the process
start by mixing of sugar and pectin with treated water at the temperature of 85 degree celcius
for 15 minutes .Then the mixture is transferred to the blending tank. Before the step,the
granular colour powder is mixed with water and transferred to the blending tank.The pulp is
mixed with water in the mixing tank and transferred to the blending tank.In blending tank,
colour ,sugar,pectin(only for apple,litchi,and orange) and pulp are properly mixed and sample
is taken for checking and maintaining the requried brix.After the requried brix is
maintained,it is transferred to the homogeniser for the uniformity of the juice .Then the juice
is transferred to ready beverage tank from where it reaches balanced tank .Initially pipes
contain water which may lower the brix of the juice.So, juice is transferred to the saver tank
where brix is maintained then juices goes back to balanced tank.
Juice is now subjected to pasturization at 96-98 degree celcius with a contact time of 5-10
seconds in a Tube Heat Exchanger in a heating medium.The tube heat exchanger works on
the principle of counter current mechanism where juice flows inside the tubes and hot water
around the tubes, both having opposite directions of their flow.Here positive pressure is
maintained (either 0.207bar or 3psi) so that in case of leakage in any of the tubes,juice and
water do not get mixed.Then juice go to cooling medium having the temperature <30 degree
celcius in a Tube Heat Exchanger. Here cold water flows around the tubes instead of hot
water.Then this juice is transferred to filler. Filling is done at 25 degree celcius because If
filled hot seal weakens and pack properties change.

Meanwhile Tetra pack packaging material roll is placed behind the machine.Above the
packaging material holder is the Strip Applicator which seals the 60% of strip on one side and
leaves 40% open.Then packaging material goes for sanitisation in the hydrogen peroxide
bath and the temperature 65-70 degree celcius, maintaining concentration 34-50% with a
contact time of 5 seconds.Hydrogen peroxide bath eliminates any contamination present on
PMI roll and sterlises it.Squeeze roller placed above the peroxide bath retains the extra
hydrogen peroxide.Hot air of 125 degree celcius is blown from above through air knife to dry
off the hydrogen peroxide remain.In Asceptic chamber, pressure roller helps in longitudinal
sealing with the remaining 40% of the strip. Juice comes via filling tube containing a probe
which fills the required amount of juice in the pack (150ml in 160ml pack).10ml is the head
space covered by nitrogen which also gets filled simultaneously.Nitrogen is added for the
stability of the pack.There is a jaw system which helps is transverse sealing.These jaws not
only seals the pack but also cuts the pack in two at 98 bar pressure. Upper and lower flaps
stick with the pack when high temperature and pressure is given.A photocell senses the mark
beneath the flap seal and conveys it to further to the conveyor.Coding is done via ink jet
coder.Then packs go through straw applicator machine,packaging on trays is done manually
and these trays go for shrink wrapping.

Tetra pack juices have six months of shelf life.Sterilization of juices is not done because
excess heat given to sucrose leads to caramelization.CIP of tanks and the tube heat
exchangers is done at sterilization temperature i.e,121 degree celcius to maintain sterile
conditions.
FLOW CHART FOR TETRA PACK MANUFACTURING:-

PULP+COLOUR+ SUGAR+
PECTIN

ARE PROPERLY MIXED IN

BLENDING TANK

HOMOGENISER

READY BEVERAGE TANK

PASTEURISAION AT 96-98
DEGREE CELCIUS FOR -10
SECONDS

COOLING MEDIUM <30

DEGREE CELCIUS

FILLER WHERE FILLING IS

DONE AT 25 DEGREE
CELCIUS

UNDER ASCEPTIC
CONDITIONS FILLING IS
DONE

INK JET CODING

STRAW APPLICATION

SHRINK WRAPPING
TESTING:-
1. Pack integrity electric test (conductivity test):-
Cut the pack in the centre into two equal halves .Fill with water and keep it in a water
tray.Put one of the wires of conductivity meter in water tray and one in the pack.If the needle
doesnot deflect , it means pack integrity is good and if the needle of the conductivity meter
deflects it shows that there is a pin hole in the pack.

2. Pack integrity dye test (erythrosine -allura red):-

Cut the pack from the centre in two equal halves. Fill 1/4th of the dye in the pack and then
take out the dye and let it dry. After drying take off the upper layer of the pack to check
whether there is leakage in the pack or not. If the colour appears on the upper surface it
indicates leakage of the pack .

3. Pack integrity seal inspection (SA, LS & TS):-

Cut the pack from two corners and make the diagonal cut from front.Then inject the dye in
the air gap.Dye should come in a straight line (wrinkles sometimes leads to leakage). Dye
coming in a straight line indicates effective strip application.

Cut along the strip and pull out the strip holding it at the angle of 90 degree.If the white layer
of the pack comes out along with the silver layer then the longitudinal seal is good.

Cut the pack in such a way that both transverse seals are separated.Take the transverse seal
and hold it between the players , pressing it and separating the layers.If the white layer of the
pack comes out a long with the silver layer then the transverse seal is good.
4. Hydrogen peroxide concentration :-( Range =35-55)
Using hydrometer density of hydrogen peroxide is checked.Taking hydrogen peroxide in a
measuring cylinder and dipping hydrometer in it gives the density of hydrogen peroxide
indicating its concentration.

5. Hydrogen peroxide residue:-

It is done using peroxide test kit containing strips. Dip the strip in the juice for 15 sec. If
colour changes to greenish blue, it indicates presence of hydrogen peroxide ( colour range -
given on the bottle). Usually hydrogen peroxide residue comes nil (range-<0.5).
6. Particle size:-
Take two drops of sample on a slide and place a cover slip over it such that no air bubble is
trapped in it. Using water rinse the stage on which slide is to be placed. Place the slide under
the eye piece and focus the microscope. Particle size should be <3 microns. The lens of the
eye piece can be rotated to rotate the scale which shows the particle size.

7. Beverage pH:-
It is checked using pH meter.

8. Product temperature:-
It is checked by the digital thermometer.
 MICROBIOLOGY LABORATORY
Soft drinks and fruit juices represent an important market within the food industry.The
increasing variety of products being released at a bewildering rate has altered the potential for
spoilage problems. Soft drinks are generally nutrient poor media that are spoiled by relatively
few organisms – usually yeasts, and a few acid-tolerant bacteria and fungi. Carbonation shifts
the spoilage flora to those organisms tolerant of carbon dioxide. Soft drinks enhanced by the
addition of low levels of fruit juice tend to exhibit similar spoilage flora to fruit juices.

Microbial problems within soft drinks and fruit juices can be divided into two groups:
(1) growth in, and deterioration of, the product by general organisms to produce spoilage;
(2) growth in, or contamination of, the product by pathogens to produce food poisoning.
Simple soft drinks such as orangeade and lemonade are too acidic for the growth of most
organisms, so that spoilage is generally by carbonation-resistant species.Yeasts usually
require a carbon source such as a hexose sugar, a nitrogen source such as amino
acids or ammonium salts, simple salts (phosphate, sulphate, potassium and magnesium ions),
trace minerals and vitamins.

LAMINAR AIR FLOW:-

It consists of High Efficiency Particulate Air (HEPA) filters. All the tests conducted in the lab
are done in the laminar air flow. Air flows outwards so micro organisms have no chance to go
in, hence, asceptic conditions.
The Petriplates which are used are sterlised in autoclave ( steam under pressure).
Temperature-Time combination in autoclave is 121 degree celcius for 15 minutes at 15 psi
pressure. All the bottles, petriplates except the sample are autoclaved.

Sterlization can be of two types:-

Wet sterlization- It is an improved method i.e., autoclave.
Dry sterlization- Oven is used for sterlization at 180 degree celcius for 2.5 hours. It takes
more time to heat up and to cool down, so it is usually not used.
INCUBATOR:-An incubator is a device used to grow and maintain microbiological
cultures or cell cultures. The incubator maintains optimal temperature, humidity and other
conditions such as the carbon dioxide (CO2) and oxygen content of the atmosphere inside.

Microorganisms have the capacity to create spores until favourable condiions are not given.
Three microorganisms are tested:-
 Mesophillic ( also called as TPC)- They are monitored at 35-38 degree celcius for 72
hours i.e., 3 days.
  Yeast and Mould (heat resistant mould)- They are monitored at 25 degree celcius for
5 days.Orange serum agar is used in juices to check Yeast and Mould and also used to
check heat resistant moulds ( in case of pulp).
 Coliform (feacal matter)- They are monitored in water at 35 degree celcius for 1 day.
It is gram negative in nature.
 Thermophillic Acidophillc Bacteria(TAB) is checked in case of pulp and sugar at 85-
90 degree celcius. BAT media is used to check TAB.In thermophillic acidophilic
bacteria testing pour plating is done.It is incubated at 45 degree celcius for 5 days.

Media used for Yeast and Mould, Coliform and mesophillic are m-green,m-ENdo and MTGE
respectively.

Plating:-
There are two types of plating-
 Membrane Filteration:Membrane filtration is a method where membrane filter of
different pore size are used.these are thin porous sheets of inert cellulose plastic
containing capillary pores of uniform size , small enough to prevent the passage of
microorganism . When we filter the sample, microorganisms cannot pass through the
membrane and remain on the filter. Through the selection of pore size , nutrients
medium and incubation temperatures , specific group of microorganisms are able to
grow and form visible colonies which can be counted.

For Total Plate Count and Coliform 0.45 micron filter is used.
In Yeast and Mould 0.8 micron filter is used, It is used for
proper growth.
 Pour Plating: is done in juices and pulps. The media or agar is poured in petriplate,
the juice (2ml) is poured in the petriplate containing media and it is properly stirred. It
is kept aside for 2 minutes until it solidifies and then incubated.
TESTING:-
1. SWAP METHOD:- The samples are taken from the mixing trolley and conveyors. It is
then transferred into the tube which contains sterlized water or peptone water, NaCl is also
used which helps to dissolve the impurities faster. 1 hour resting period is given where micro
organisms are transferred to water in the tube and then membrane filteration is done.
2. MICROBIOLOGICAL TESTING OF AIR:- Its done using air sampler where agar is
poured into a plate which solidifies .It is kept in contact with air for 10 minutes in the
processing area and then incubated.Its range should be less than 100 CFU(colonies forming
unit).
3. MICROBIOLOGICAL TESTING OF SUGAR:- The sample is prepared by dissolving
1gm of sugar in 9 ml sterilised water and then membrane filteration is done to check
mesophillic ,yeast and mould growth.
4. MICROBIOLOGICAL TESTING OF PULP:-To check heat resistant mould , yeast and
mould, total count, mesophillic and coliform growth.A solution is made by mixing pulp and
water in same quantity which is then subjected to heat shocks in water bath for 10 minutes at
75-80 degree celcius so that vegetative spores of micro organism present in pulp gets
activated. then pour plating test is done.
5. MICROBIOLOGICAL TESTING OF PREFORM AND CLOSURE:-The preform
and closures are submerged into sterilized water for 4-5 minutes.
6. MICROBIOLOGICAL TESTING OF BOTTLE:-Pour 100 ML sterilized water in the
bottles and shake well.Test the water by membrane filteration.
Bottle for testing comes after blow molding wrapped immediately by AL foil to prevent
microorganism to contaminate.
7. MICROBIOLOGICAL TESTING OF CSD FINAL PRODUCT:-Write down date,
batch number,name and volume of the bottle on petriplates.Wash the membrane filter with
sterlized water first and then place the filter paper on membrane filter and put on the tumbler
and pour 20ml sample. Take out the filter paper and place it on the absorbent pad containing
media (m-green) and then incubate the petriplates at 25±2 degree celcius for 5 days.
Blank sample is also prepared in which sterlized water is taken on filter paper and then placed
on absorbent pad to check whether sterlized water is contaminated or not.
8. MICROBIOLOGICAL TESTING OF HOT FILL FINAL PRODUCT:- Write down
date,batch number,name and volume of the bottle on petriplates. Then take sample 2micron
from micro pipette and discard the tube. Add orange serum agar and shake to homogenise it
and let it stand for 2-5 minutes to solidify. Incubate at around 25±2 degree celcius for 5 days.
Blank sample is also prepared where OSA is taken in petriplate to check whether media is
contaminated or not.

SAMPLE TPC COLIFORM YEAST MOLD

Water Less than 25 Nil -
Maaza Less than 25 Nil Less than 5
Beverages Less than 25 Nil Less than 10
Tetra pack maaza Nil - nil
Tetra pack juices Nil - nil
 CLEAN IN PLACE:-

Clean-in-place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process
equipment, filters and associated fittings, without disassembly.

3 STEPS CIP :

 Pre –rinse for 10 minutes at ambient temperature .

 Hot water for 15 minutes at 85-90°C.

 Final rinse for 10 minutes at ambient temperature .

5 STEPS CIP :

 Pre-rinse for 10 minutes at ambient temperature

 Hot lye for 15 minutes at 60°C-77°C with 1.0%-1.5% caustic concentration .

 Water rinse for 10 minutes at ambient temperature.

 Hot water for 15 minutes at 85°C-90°C.

 Final rinse for 10 minutes at ambient temperature .

6 STEPS CIP :

 Pre-rinse for 10 minutes at ambient temperature .

 Hot lye for 15 minutes at 60°C-77°C with 1.0%-1.5% caustic concentration .

 Water rinse for 10 minutes at ambient temperature.

 Acid rinse for 20 minutes with 3% w/v phosphoric acid .

 Hot water for 15 minutes at 85°C-90°C.

 Final rinse for 10 minutes at ambient temperature.

 SENSORY
It is the interaction of the senses where aroma, appearance, sound, flavour, mouth-feel and
hearing is analyzed.

Some of the off odours/off-notes are:-

 Sulfurous
 Earthy/Musty
 Medicinal
 Metallic
 Fruity-Acetaldehyde
 Plastic
 Fruity
 Burnt Caramel
 EFFULENT TREATMENT PLANT
Effluent is an outflowing of water or gas from a natural body of water, or from a manmade
structure.Liquid waste that is sent out from factories or places where sewage is dealt with,
usually flowing into rivers and lakes.Industrial wastewater treatment covers the
mechanisms and processes used to treat wastewater as a by-product of industrial or
commercial activities. After treatment, the treated industrial wastewater (or effluent) may be
reused or released to a sanitary sewer or surface water in the environment.

The waste water is collected into the settling tank where the heavy sludge settles down.It then
passes to the oil and grease tank which traps the oil and grease with a help of belt and collects
it in a drum.Screen chambers are used to trap external material like labels or closures.From
oil and grease trap ,it then moves to the sump tank where three pumps are used to transfer
water from the sump to equilizer.In equilization tank 1,the volume is 267m3 and caustic is
added if pH is low.In equilization tank 2 ,the volume is the same i.e., 267m3 where pH of
water is maintained and backwashing water from WTP's comes here.When Ph is maintained,
then water goes ahead.The water then passes to primary clarifier where lime is added into the
water which separates the sludge and polyelectrolytes is added which helps in bonding of
sludge. It then passes to saff tank(submerged aerobic fixed film) where nutrification is done
by the media and its volume is 230m3.The water then passes to aeration tank where bacteria
is provided with food ,then passing through filters,its transfered into secondary clarifier
where claridon used for fast settling where pH is 7-8 and then water finally comes into
discharge tank where bacteria is killed due to chlorine is added.It then is discharged into lakes
and fields.
 FLOW CHART OF EFFULENT TREATMENT PLANT:-

INFLUEENT

COLLECTION SUMP

SETTLING TANK

OIL & GREASE TANK

EQUALIZATION TANK 1&2

PRIMARY CLARIFIER TANK

1&2

SAFF TANK

NEW AERATION TANK

AERATION TANK

SECONDARY
CLARIFIER
 TREATED WATER TANK

SMBS

SAND FILTER

ACTIVATED CARBON
FILTER

REVERSE OSMOSIS

SPECIFICATIONS OF FINAL DISCHARGED WATER:

 Ph: 6.5-8.5

 TDS less than 2000PPM

 Chlorine :NIL

 TSS less than 50PPM

 BOD less than 30PPM(PPCB) ; Less than 50 as per KORE

 COD less than 250PPM

 DO greater than 1PPM

ONLINE MONITTERING SYSTEM

1. pH AND TDS: Checking PH AND TDS of water sample by pH meter and TDS meter.

2. BOD Test

Aim:To check the biological oxygen demand of water

Procedure:Taken 432ml water sample in a BOD sample bottle.

Placed on magnetic stirrer.

Placed Oxy Tube on the neck of bottle.

Add 2 pellets of NaOH.

Screwed tightly.

Pressed S,M switch together till value displayed is 0.

Kept sample for 5 days at 20 degree in incubator.

Taken average reading.

FREQUENCY OF TESTING:

For inlet water: weekly

For discharged water: daily

3. COD Test :

Aim : To check the chemical oxygen demand of water.

Procedure:

Properly mixed solution A solution B and sample as given in the table.

Kept the tube at 120-140 degrees temperature for 2 hours in thermoreactor.

Cooled the tube and mixed for 10 minutes.

Range is checked( reading at 605 nm in 10mm cuvette)

CALCULATION=2249 x ABSORBANCE

4. OIL AND GREASE TEST:

Aim : T o check oil and grease in ETP water

Procedure:

Taken 200ml sample in 50ml flask.

PH is reduced to 3.5 to 4.0 with help of HCL.

Sample is added in separated funnel.

Then added 5ml petroleum ether in separating funnel.

Shake it vigorously and left it for 1 minute.

Oil and grease will be formed in the upper layer .

 Remove the solution from separating funnel , collecting oil and grease of upper
layer in another beaker.

Repeat this step 4 times.

Collected and weighed the sample.

FORMULA: ( W2-W1)*1000/SAMLE VOLUME(200ML)

Where

W2=weight of oil and grease in the beaker .

W1= weight of empty beaker