Chapter one

1.1. Background

East Africa Bottling Share Company (EABSC) is one of the beverage companies
in Ethiopia which produces the coca-cola company products: coca-cola, coca-
cola light (sugar free), fanta orange, fanta pinaple, sprite, shweeps tonic, crystal
(carbonated water)

The first Coca-Cola bottler in Ethiopia was created in 1959 as the Ethiopian
Bottling Share Company. As the business expanded a branch was established in
Dire Dawa in 1965.

The two plants were nationalized in 1975 and operated as a public company until

1996. With the introduction of the privatization program, Ethiopian entrepreneurs
bought the two companies.

Coca-Cola SABCO and Ethiopian Bottling Share Company signed a joint venture
agreement on 19th May 1999. The name of the company is changed to East
Africa Bottling Share Company (EABSC) .This ‘marriage’ has proven to be a
perfect match which has brought about many positive changes, such as people
development, which is mandatory to grow the business. In line with this, a fully
equipped training centre was established as soon as the joint venture was
signed.

In June 6, 2003 after a major upgrade of the Addis Ababa plant it was officially
inaugurated by the Ethiopian President. In September 2007, a third production
line was installed in the Addis Plant, increasing the installed capacity by 75%.

East Africa Bottling Share Company is committed to developing and maintaining

an integrated Occupational Health & Safety, Environment and Quality
Management System based on ISO 9001:2000, ISO14001:2004 and
OHSAS18001:1999.
The plant achieved HACCP certification since 2005 by BVQI.A silver award on
product and package quality was given by Coca Cola Company in 2006.

1.2. Introduction

In EABSC material and product integrity is ensured at 3 key levels

• Level 1: Procurement and Outsourcing:
EABSC is buying ingredients and materials only from Division authorized
suppliers list that is provided by the Coca-cola Division office. The authorized
suppliers list is updated every year by the Division Office
Based on the suppliers audits outcomes and the bottling plants feedback on the
Supplier performance. The Purchasing manager ensure that each supplier being
used to supply any type of ingredient, chemical, auxiliary material, packaging
item, etc suppliers has the latest specifications and requirements.
• Level 2: Quality control and testing
For received goods
All received ingredients, chemicals and packaging items are meticulously tested,
properly stored and handled. They are released only if established criteria are
met.:
For processing and finished products
Quality control and testing are conducted at appropriate stages of processing.
Finished products are tested by quality control testing methods in the plant:
Quality control and testing are also tested products from the market place to
ensure that EABSC is delivering to consumers high quality products.
• Level 3: Control of nonconforming product
In order to ensure that nonconforming materials and products are inadvertently
used.
Process integrity
Process integrity is ensured at 3 levels:

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• Level 1: Identification of processes
Plant’s system procedures have clearly identified processes and their interaction.
􀂃 High level process map;
􀂃 Master Control Document list
• Level 2: Process monitoring
By knowing processes as identified at level 1, plant’s TCCMS management
system has established procedures to manage them i.e. ensure that expected
outputs are met for each process.
ISO 22000 (HACCP) is fully implemented to ensure food safety available as
tangible evidence.
List of documented procedures is available in Master Control Document list
• Level 3: Maintenance
Documented procedures have been established to ensure that infrastructure and
work environment is properly maintained:
• EOSH performance are monitored and measured by EOSH coordinator
Training
The Plant is fully aware that training is one of the keys for maintaining a
successful Organization .Plant’s SHEQ management system includes key
activities like:
• Identifying skills and competencies required for each function and job;
• Evaluating the gaps between current and required skills and competencies;
• Eliminating the gaps by providing appropriate training;
• Evaluating the effectiveness of training conducted.
Audit
As auditing is an important activity that helps prevent problems and drives
continual improvement, EABSC management system has addressed this activity
and defined all the details of the process in the internal audit procedure

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 Chapter Two
2.1. The production process
2.1.1. Cleaning & Sanitation

The program covers the cleaning & sanitation of all processing equipments and
processing rooms .It covers the steps from preparation of cleaning and sanitizing
material up to performing the cleaning and sanitation and measuring
effectiveness of cleaning and sanitation program. To prevent contamination of
ingredients or final products that comes in contact with processing equipments.

2.1.2. Cleaning
Is the washing of equipment and pipelines, or other surfaces to remove residual
product and unwanted material.

2.1.3. Sanitation
Is the treatment of clean surfaces and equipment by a process that destroys all
pathogenic bacteria and substantially reduces the population of all other
microorganisms.
2.1.4. Pungent Products
Are those flavored products that cannot easily be rinsed from processing
equipment and therefore require a detergent cleaning to remove traces of the
flavor components from the equipment

2.1.5. Scheduling

Cleaning and sanitation program is scheduled to all processing equipments in

conjunction with the maintenance plan of the plant. All processing
equipments/machineries/or processing room are clean and sanitized at all times

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to prevent contamination of product. A full 5-step cleaning & sanitation is
performed every 48 hours on processing machineries

2.1.6.. Cleaning and Sanitizing Agents

The cleaning and sanitizing agents used in the plant are hot water, sodium
hypochlorite and caustic soda or tri-sodium phosphate (TSP). The suppliers
submit the certificate of analysis and letter of conformance to the Coca-Cola
requirement.

2.1.7. Performing Cleaning & Sanitation Activities

Cleaning & sanitation activities to all processing equipment are performed as per
the schedule i.e. for syrup room, bottling hall, and container washer. The
cleaning & sanitation performed could be rinsing, three steps or five steps
depending on the frequency or flavour type for product change over. Refer to
three steps & five steps procedure for detail. The cleaning & sanitation is also
done during product change over as per the change over matrix .On a day-to-day
basis, any type of sanitation on processing machinery are recorded on the daily
quality control report sheet.

2.1.8. Monitoring the Cleaning & Sanitation activities

The frequency, method of application of cleaning & sanitizing agents, their

concentration and contact time is checked during the process.

2.1.9. Rinsing, three Steps & five Step CIP

2.1.9.1. Rinsing

Is the process of rinsing the lines and machines with treated water to remove any
soil load. The lines and machines are rinsed until the appearance of the rinse
water becomes clear of any flavor taste or color.

2.1.9.2. Three Steps Using Hot Water

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This step has found to be effective when there is no need to use a detergent for
cleaning and it is necessary to sanitize the equipment. The equipment is rinsed
with treated water to remove any remnant product from. Then it will be cleaned &
sanitized with hot water (75 OC), the hot water acts as cleaning agent and a
sanitizing agent to destroy microbial contamination. The water that circulate is
kept circulating for 15 minutes after the exit temperature of the water is above 75
O
C. If the exit temperature of the hot water can be maintained at or above 85 OC,
the re-circulation time can be reduced to 10mins. Then the equipment is rinsed
with treated water to cool the equipment.
2.1.9.3. Five Steps

This procedure is done to all equipments in syrup room & processing room (filler,
blender, piping systems) every 48 hours .First the equipment is rinsed with
treated water to minimize the soil load. This removes most of soluble material
and increases the effectiveness of the cleaning agent. Then flushed with hot
caustic solution (75oC) of 1.5 %( w/v) to loosen and remove any residual soil
particles from the surface of the equipments. Then rinsed with treated water. This
rinse prevents deposited of the soil up on the cleaning surface and removes any
residual detergent. All traces of detergent solution are removed by rinsing with
treated water .Lastly it is sanitized with hot treated water to destroy microbial
contamination using hot water.

2.27. Bottling Hall

2.7.1. Proportioning, Carbonating, and filling Equipment

At the ends of a production run, all syrup and product remaining in the system is
completely drained. The system is completely flushed with treated water to
remove remaining syrup and product residue. If there is a product change over,
the necessary cleaning procedure will be followed according to change over
matrix .All samples and drain valves are opened during rinsing, sanitizing, and
flushing to ensure that no dead spots containing syrup, product or sanitizing
solution remain in the system.

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2.7.2. Equipment Exteriors
All equipment exteriors are thoroughly washed and rinsed with powder soap and
cold water to remove syrup, product, and any extraneous material

2.7.3. Conveyors
All conveyor systems are thoroughly rinsed with water including trays to remove
soap lubricant and mold, which has build up during the days of operation with
high-pressure spray is particularly used for this purpose.

2.7.4. Crowner
Crown dusts are removed from the crowner at least twice per shift. An increased
frequency may be needed, depending on the dusting tendency of the crowns in
use. Crown hopper and chutes are emptied at the end of the day’s production
and product changeover. Crown hoppers are cleaned using a clean, dry cloth
and a clean dry brush to get in to corners. Weekly crowner throats or closure
application heads are washed with water to remove any product and dust build
up. Water is not used to clean hoppers.

2.7.5. Drains
All drain of debris; broken bottles crowns and the like are cleaned by lifting the
drain covers

2.8. Cleaning Bottle & Crate washer

2.8.1. Bottle Washer

2.8.1.1. Pre Rinse, Warm Water, Cold Water & Fresh Water Compartments

The Pre rinse, cold water, warm water, fresh water compartments are inspected
at least once in a shift and flushed with soft water. The pre rinse, warm water,
cold water and fresh water compartments are always drained and flushed at the
end of production and leave dry until the next use.

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These compartments are cleaned at least weekly and if not in use they are
cleaned daily depending on the stoppage plan as per maintenance and sanitation
schedule.
2.8.1.2. Rinse Nozzles

All the nozzles are inspected for clogging and alignment twice per shift. The
sprays jets are brushed on line one at least once per Shift. Any materials causing
clogging or blocking are removed by brushing. The jets are disassembled at least
once in a week or as necessary and thoroughly clean.

2.8.1.3. Washer Exterior

The body of the washer is washed using powder soap daily and the stainless
steel parts are kept shiny at all times

2.8.2. Crate Washer

Create washer is cleaned at least two times in a shift .The water in the tanks is
cleaned at all times and the filters are cleaned at least twice in a shift, the water
is changed once in a day

2.9. Cleaning & Sanitation Syrup Room

2.9.1. Syrup Tanks & Piping System

After the syrup is produced any syrup residual left is drained completely during
tank change over. The tanks and piping are cleaned as per cleaning and
sanitation matrix, to ensure that there is no color and odor of previous product in
rinse water.

2.9.2. Simple Syrup Filter Press

The filter sheets are cleaned with treated water to remove any sugar residue on
the simple syrup filter press.

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2.9.3. Concentrate & Beverage Base Handling Equipments
These equipments are rinsed with treated water to make sure all traces/
remnants/ are cleared.

2.9.4. Walls, Floors & Drains

All floors, walls, all drains of debris of the syrup room are cleaned with cleaning
detergent

2.9.5. All Equipment

Five steps Cleaning & Sanitation will be performed to all equipments in syrup
room as per procedure. The sanitation effectiveness is verified by doing
microbiological analysis on weekly basis and if the sanitation is not effective the
sanitation will be done again.

2.9.7. Cleaning and Sanitation Matrix

To COKE FAOR SPRITE F.ANANAS TONIC CRYSTAL COKE

LIGHT
Filling line

Syrup tank

Filling line

Syrup tank

Filling line

Syrup tank

Filling line

Syrup tank

Filling line

Syrup tank

Filling line

Filling line

Syrup tank
Syrup tank
From

COKE NA RW RW 3ST RW 3ST RW 3ST RW 3ST 3ST 3ST 5ST 5ST

FAOR 3ST 3ST NA RW RW 3ST RW 3ST RW 3ST 3ST 3ST 5ST 5ST

SPRITE 3ST 3ST RW 3ST NA RW RW 3ST RW 3ST 3ST 3ST 5ST 5ST

F.ANANAS 5ST 5ST 5ST 5ST 5ST 5ST NA RW 5ST 5ST 5ST 5ST 5ST 5ST

TONIC 3ST 3ST RW 3ST RW 3ST RW 3ST NA RW 3ST 3ST 5ST 5ST

CRYSTAL 3ST 3ST RW 3ST RW 3ST RW 3ST RW 3ST NA RW 3ST 3ST

COKE 3ST 3ST 3ST 3ST 3ST 5ST RW RW 5ST 5ST 5ST 5ST NA RW
LIGHT

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Definitions
N.A – Not Necessary
R.W - Rinse with Treated Water
3 ST – 3 Steps with Hot Water
5 ST – 5 Steps with hot Caustic and water

2.1.2. Container Washing

2.1.2.1. Washer

Is a bottle or crate washing machine, which has different compartments for step-
by-step cleaning of the company bottles and crates?
The Bottle washer operation is prepared in order to remove all dirt from inside
and out side of bottles and to kill moulds, yeasts, and any pathogenic bacteria
from the bottles. Before bottle washing operation is began the washer itself is
cleaned thoroughly.
Then all water compartments will be filled with water and caustic compartments
will be filled with pre heated caustic. The temperature & concentration of caustic
in all caustic tanks will be checked for minimum requirements before starting to
feed the washer with bottles. The temperature and concentration in the main
caustic tank should be > 62 OC, and >2.0% respectively.
If these conditions are met then starting up of the washer can be done. If the
temperature is below 60 oC the washer will be warmed-up. the machine will be
run for 10 min before feeding bottles in order to stabilize the temperature
through out the machine. If the conditions stated in step one are met, then feed
the bottles to the washer and run the machine
2.1.2.2. Monitoring the Bottle Washer Operation Condition

Bottles to be filled with product should be sterile and free from residual detergent.
The minimum allowable condition of the bottle washer operation is as follows:
1• Temperature: Minimum 60 °C
2• Caustic concentration: (2.0-3.0)% caustic (as NaOH)
3• Min. soak contact time: >= 5 min. (in at least 1 comp.)
4• Rinsing with potable or treated water; chlorine residual 1–3 mg/l.

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5• Local laws and regulations are followed.
6• Pre-Final Rinse pH 7.5± 0.5

All pressure gauges, conductivity meter, & thermometers fitted on both line
washers are calibrated regularly as per the procedure detailed in Calibration
Program of the plant to ensure that they are working properly.

Any changes to the above container washing condition must be tested and
verified through Division Quality Assurance to provide the same microbiological
level and degree of cleanness.

The following parameters are checked while the machine is running to ensure the
above conditions are met or not.


if the nozzles are properly spraying or not (Once in a shift).

Rinse pressure and jets alignment (Once in a shift). Final rinse pressure
must be within the range of 2.8gm/cm 2 to 4.2gm/cm2

the strainers in pre-rinse, warm water & cold-water tanks. (Once in a shift)

the final rinse chlorine residual. (Every Four Hours)

Microbiology for final rinse water as per microbiological monitoring
program (Weekly).
 The caustic solutions level in the tanks.

Concentration of caustic in all the caustic compartments, appearance,
odour & temperature of the caustic solution as per prior to start up and
every four hours interval.

the thermal difference between tanks not to exceed 25 0C to prevent
bottles from thermal shock
 In addition to the above, quality control checks are performed on the bottle
washer

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2.1.2.3. Bottle Discharge

The bottles discharged from washer are checked for proper cleaning and rinsing.
This include

Caustic carry over

Mould carry over test for the first set of washer discharge and every four
hours.

Visual inspection for cleanness and any foreign matter as per container
program.

Bottles with moisture

Chip neck or cracked bottles

None flavour bottles
Upon inspection, if the bottles meet the requirement, they are released to the
filler or if still dirty they will be sent back to the washer in feed for rewash. If the
condition of the bottles is unusable (need for manual washing), then they will be
taken out from the line through the return conveyor and putted. The bottle
inspectors give feedback for washer operators and QATs in the case of too much
rejects at the sighting station.

2.1.3. Filling and Crowning

Filling and crowning is the process of mixing the product in the blender as per the
procedure in carbonating & blending, and filling in to washed bottles, which are
verified to be clean by inspection.

2.1.3.1. Preparing the filler & crowner

Preparing the filler includes adjusting the stem of vent tubes, cleaning the valves,
and the entire system, counter pressuring etc .Clean and sanitize the filler as per
the procedure in cleaning and sanitation program .Rinse the filler with beverage
blended that has a lower brix used for adjusting on the blender to remove any
extraneous water left in the filling valves. Then transfer the properly blended
beverage to the filler, fill few bottles and crown for laboratory test on

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  Carbonation
 Brix
 Net content
 Odor
 Taste
 Color
 Appearance
 Date code
 Crown crimp
If it is with in specification then release the product If not reject the product and
rinse the filler with the product in the filler bowl. Then adjust the setting of the
blending machine and pump in another batch from the blender and repeat the
test.

2.1.3.2. Monitoring the filling & Crowning process

The filling and crowning process is monitored throughout the production shift
every 30 minutes. This includes checking the following parameters,
 The net content and the crown crimp of the bottled product at least once
per shift (at start up) and during changeover.
 Brix and gas content of the product.
 The number of bottle bursts that happen on the filler as this can help in
identifying areas where problems are being seen (like high washer water
temperature, excessive scuffed bottles and the like)
 The full bottle inspectors also control the filling process. They inform to the
filler operators if contaminated, under fill and overfill bottles are too much
on the line.

2.1.4. Syrup Manufacturing

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Syrup manufacture involves preparation of simple syrup in one tank, its filtration
into a second tank, and thereafter conversion to final syrup (also called flavored
or finished syrup) through addition of concentrate or beverage base.
All equipment coming into contact with ingredients, syrup, or finished product in
the course of preparation, handling, and storage are of sanitary design and free
draining.
There is sufficient clearance between the top of tanks and overhead structures,
including the ceiling, to permit access of personnel and equipment for operation,
maintenance, and cleaning and sanitation. All equipment coming into contact
with ingredients, syrup, or finished product are made from approved materials
and are capable of being properly sanitized. Stainless steel (types 304 or 316)
satisfies all requirements used for construction of syrup handling equipment. It
has a bright appearance, it is impervious to syrup, it may be fabricated without
too much difficulty, and it is capable of taking a high polish.
All stainless steel product contact surfaces have a polished finish. Syrup is
viscous and thus adheres to a rough surface. Better drainage is accomplished
through the use of a highly polished inside surface. Every contract or purchase
order for stainless steel processing equipment must specify that “all stainless
steel parts in contact with the product shall be of AISI Type 304 or 316. Any parts
that are found to be not of these two types shall be replaced by the manufacturer
free of charge to the purchaser or at the manufacturer’s expense.”

2.1.4.1. Pre Coating

The process of coating the filter sheets, which are in the filter, press, by filter aid
to maximize filtration.
2.1.4.2. Filter Aid
A cellulose material or diatomaceous earth used as a filtering medium.
2.1.4.3. Body Feed
The filter aid added to simple syrup is often Called Body feed.
2.1.4.4. Filtration
The process of separating solids from a liquid by means of porous substance
through which the liquid passes

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2.1.4.5. Simple syrup
Is filtered solution of nutritive sweeteners before the addition of Concentrate or
Beverage Base?
2.1.4.6. Brix
Percentage by weight of sucrose in the solution

2.1.5. Preparation of Simple syrup

2.1.5.1 Dissolving the Sugar

Firstly the simple syrup tank is filled with 5627 liter of treated water and then
heated to 800 c.10129 Kg of sugar is added while it is agitated slowly.
Once the dumping of the required amount of sugar is finished, heat up the simple
syrup to a temperature of 80 0c.Effective agitation is needed to formulate uniform
solution. Otherwise, sugar will be settled at the bottom of the tank. Continue
agitation until all the sugar is dissolved. If the sugar is completely dissolved, then
the next step which is filtration.

2.1.5.2. Pre coating the filter press

The pre-coating tank is filled with water and an appropriate quantity of filter aid is
added while the agitator is running. Then gradually the outlet valve of the pre
coat tank is opened and the solution is allowed to flow in to the filter press. Then
the mixture is circulated through the filter press and back to the pre-coat tank to
form “Cake” with in each frame of the filter press. Circulations of the solution of
filter aid continue through the filter press until it is completely clear. This indicates
that the filter aid has been properly deposited. After the pre coating is clear,
slowly open the simple syrup outlet valve while closing the pre coating valve at
the same time and start circulating the sugar solution to the filter press.
Continuous flow during circulation is essential. Sugar is circulated until the
appearance of the sugar meets specification

2.1.5.3. Transfer Simple syrup to final syrup Tank

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Once the solution is clear the flow should be directed to the final syrup tank,
again being careful not to interrupt the flow through the filter. To avoid air in the
simple syrup, the simple syrup tank agitator is put off before the level of the liquid
in the tank reaches the blades. The entire simple syrup gets in to the final syrup
tank by pushing the ruminant of simple syrup out of the filter press. This is done
by adding the volume of water equal to the capacity of the filter press and feed
lines in to the simple syrup tank to push the simple syrup completely. As soon as
the water leaves the tank, stop the pump and close the valves. The filtration
process is completed. After simple syrup filtration is completed check Brix,
appearance (turbidity & colour) taste, and odour as per the procedures in
standard method manual

2.1.6. Final Syrup Manufacturing

2.1.6.1. Final Syrup

The final syrup is the final out put of syrup manufacturing process. It is a
homogenous mixture of simple syrup plus Concentrate or Beverage Base.
2.1.6.2. Beverage Base
The concentrated component parts of flavoring and other materials which, when
mixed with sweeteners (Nutritive or non nutritive), water, and usually carbon
dioxide, produce the final syrups and beverages for all company products except
Coca-Cola and Coca-Cola Classic
2.1.6.3. Concentrate

The liquid parts containing the flavoring components, coloring, and acids
manufactured by company concentrate plants. They are used in the preparation
of Coca-Cola syrup.
2.1.6.4. Adding Concentrate or Beverage Base and Mixing

After filtration is completed, the simple syrup is verified for the standards of
 colour
 Turbidity
 Brix

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  Appearance
 Taste and
 Odor
 microbiology
Then it is checked
 the Concentrate container is in a good condition,
 Count carefully the containers and the parts to make sure they align with
the number of units to be prepared.
 dry parts must be pre- dissolved in treated water set aside for that
purpose.
 each part must be mixed thoroughly in to the bulk of the syrup before the
next part is added, otherwise syrup can result in adverse reaction between
the parts
 add the concentrate or beverage base in accordance with the mixing
instruction
 rinse the Concentrate or Beverage Base containers thoroughly with
treated water which is held from simple syrup manufacture, and add the
rinse to the final syrup tank.

Note: When adding Concentrate, any crystal remaining on the screen after
rinsing is dissolved in warm treated water and added to the batch.

Then it is agitated thoroughly for at least one hour after adding all concentrate
and beverage base
2.1.6.5. Sampling & Testing

The agitator is stopped and allowed the syrup to stand for 5 minutes to allow any
bubbles to escape. Take sample and test the final syrup for brix and measure its
volume. If the syrup Brix is above the standard the brix is adjusted by adding the
required amount of water. The results are recorded on syrup manufacturing
report form.

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2.1.6.6. Release the syrup to Production

If the brix is ok the final volume of the syrup will be recorded and the syrup is de-
aerated for one hour before realizing to production. All final syrup are used on the
day of manufacturing date. But when this is impractical, the following guidelines
apply to their storage.

1. Coca-Cola = 7days of Manufacture

2. Sprite, S.Tonic = 14 days of Manufacture.
3. Fanta Orange = 1 day of Manufacture

o
These storage periods apply only if the syrup temperature remains below 25
C/77 o F
2.1.6.7. Records

Syrup Manufacturing records include the following information and kept for two
years in QAM office.

 Syrup Batch number

 Flavor
 Batch size
 Date of Manufacture
 Quantity of sugar used
 Quantity of water used
 Concentrate Batch number

2.1.7. Date Coding

The date code is used to promote proper stock rotation, removal of over aged
product from the market, and effective product traceability.
2.1.7.1. Production date code
A code used for traceability which includes plant, time and date of production.

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2.1.7.2. Open style date code
a style of coding which can be easily understood by consumers without training
or decoding aids, for example, 01/04/2005.

2.1.7.3. Durability period

A time during which a product is fit for use.

2.1.7.4. Requirements

Enforce a no code/no run policy. If the line is not capable of applying legible date
codes (open date style code and product date code) to packages, filling on the
line does not occur.
• Each package must have both:
− a production date code that identifies the production plant and
date; and
− an open style date code or a durability label.
2.1.7.5. Monitor the print Quality

All bottles are removed from the line whenever illegible or un-date coded product
is identified. At all condition the policy of “NO CODE NO RUN” is applied by all
personnel’s at all time. The filler operator makes sure that the date coding comes
back to its original condition.
The Date code print is checked on the line according the specific checklists
provided. Date Code checklist is filled to monitor the effectiveness of the date
code.

2.1.8. Carbon Dioxide Production

2.1.8.1. How the System Operates

The CO2 gas is produced from the complete combustion of a liquid or gaseous
fuel.
a) Fuel is fed to the combustor under carefully controlled conditions to obtain
maximum CO2 in the flue gas without trace of smoke. A CO2 analyzer

18
 and smoke test gun are provided to assist regulation of fuel to obtain
complete combustion.
b) Air is introduced to the combustor through a positive displacement type
blower. From the Brower the air is divided into two streams, primary air
and secondary air. The primary air atomizes the fuel oil at the combustor
head. The secondary air completes combustion of fuel within the
combustor and firebox. Both streams of air are thoroughly mixed together
within a stainless steel cone incorporated in the combustor.
c) Flue gas passes through the re-activator firebox and tubes, transferring
heat to the absorption solution. The flue gas then passes through the
scrubber tower where it is water washed and cooled before entering
Absorber tower.

Chemical Reaction

Fuel gas + O2 CO2 + Impurities

2.1.8.2. Absorption

The absorption solution is a low concentration aqueous solution made up from

MEA, soda ash, copper carbonate and water. This solution has an affinity for,
and will absorb CO2. The operation of the CO 2generator consists of the
continuous circulation of the absorption solution, which is cooled and
subsequently absorbs CO2 in the absorber tower. The” Strong Solution” is then
heated, releasing its CO2 content in the stripper tower, to become “Weak
Solution”
Clean cool flue gas enters the top of the Absorber tower, passing through to the
base. Weak solution is pumped from the re-activator via the heat exchanger and
solution cooler, to be distributed at the top of the Absorber tower and mix with
flue gas content in the flue gas is selectively absorbed into the solution on the
way and the solution, charged with CO2, enters the base tank as “Strong
Solution”.

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2.1.8.3. Monitoring Operation

Fuel is t regulated to avoid smoke or low CO 2 Content in the flue gas . MEA is
charged when the strength is below 7.5% (Add 2 liters of MEA per 1000 kg of
CO2 produced to keep the solution at operating strength) .The PH dosing tank
must be filled regularly with 25kg of caustic soda in 125lt of water. The
permanganate solution (which is used to avoid impurity gases) is changed after
100hrs of operation or if the purple color of the permanganate solution is
changed

2.1.8.4. CO2 Quality Test

The CO2 produced is checked for quality conformance before it used in the
production of beverage. CO2 produced is checked for its quality for
 odor,
 purity ≥99.9%,
 Appearance
 taste
 Other un wanted gases

Impurity gases Permissible range

Ammonia 2-30ppm
Acetaldehyde 100-1000ppm
Carbon disulphide 0.1-10mg/l
Carbon monoxide 2-60ppm
Formaldehyde 0.5-5ppm
Hyderogensulphide 0.2-7vol.%
Nitrogen dioxide 10-100ppm

2.1.9. Water Treatment

Water constitutes 85% of coca cola products therefore it is important for uniform
quality coca cola products .EABSC uses well water for the production .Although

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well water is relatively free from most of turbidity ,colour organic matter and
bacteria. However in passing down through the earth it has been in extensive
contact with minerals and has too much soluble minerals content. If the mineral
content of water is too high it will cause the water to have a salty taste and
therefore make it unusable for the production. This alkaline mineral content has a
property of neutralizing one of the basic acidulent flavours of the coca cola and
for this reason the alkalinity of any water always be reduced to a very low level.
The water treatment system includes enhanced filtration, alkalinity reduction,
disinfections, carbon purification & polishing filtration processes.

2.1.9.1. Why water must be treated

Water may be of good flavor in it self and perfectly safe to drink, yet it can be
responsible for many defects in “coca cola”. Harmless substance dissolved or
suspended in un treated water may react with the ingredients of “coca cola
“syrup to produce one or more defects .The most prevalent of these to occur in
the bottled beverage are:
 Poor flavor
 Stringy and flaky sediments
 Unsightly rings at the neck of the bottle
 Turbid beverage
 Poor carbonation and foaming at the filling machine
There fore practically every water requires treatment which will remove from it
the reacting substances responsible for an inferior beverage .only then can it
be used safely in preparing “coca cola”

2.1.9.2. Reverse osmosis

Reverse osmosis is a process that separates a solute from a solution by forcing

the solvent to flow through a membrane by applying a pressure greater than the
normal osmotic pressure.

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2.1.9.3. Sand Filtration

Sand filter is used as a strainer to catch any suspended matter that may have
been carried along with the water.

2.1.9.4. Carbon purification

After the water has been passed through the sand filter it then passes through a
bed of activated carbon which is specially treated charcoal of very high degree of
activity .The primary function of carbon bed is to remove chlorine from the water.
It is necessary to remove this chlorine before the water is used in preparing
products because any chlorine carried into the drink will have a bad effect on
flavor. Carbon will also absorb organic impurities responsible for off taste and
odors
2.1.9.5. Disinfection

The water is finally exposed to UV light to kill any microbiological organisms that
would be found in the water.
2.1.9.6. Monitoring & Record
IF the following parameters are met then continue running of the plant and
monitor the parameters regularly but if they not met appropriate corrective action
should be taken. The corrective action may require stopping the specific part of
the plant for maintenance while running the others.

 PH = between 5 & 8.2

 Maximum temperature = 30oc
 SDI < 5
 UV = between 50 & 100%
 Conductivity < 95
 No trace of chlorine after carbon filter & after UV
 Free of any microbiological organisms

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 Chapter three
3.1. Quality control and testing (Quality Assurance Laboratory)

3.1.1. Microbiological Monitoring

This program is used to guarantee the quality of product by ensuring the

effectiveness of cleaning and sanitation and to follow up whether GMP is applied
during the production process. This program covers all the steps starting from
sampling up to microbiological testing of ingredients, intermediate products, final
beverage, and follow-up activities.
The following tests are performed

 Total count & coli form for washed bottles, final rinse water, process water
& raw water.

 Yeast & mold count for simple syrup, final syrup & final beverage.

3.1.1.1. Microbiological Testing schedule for ingredients and products

Sample type Test /Attributes Sample point Specifications / Minimum

Standards CFU Frequency
Raw water Total count Before the RO Total count less than Once in a week
plant 500/mL
Coli form count Coli form count = 0/100mL
Container final Total count Close to the point Total count < 25 /ML Once in a week
Rinse water of use (Each
Washer)
Coli form count Coli form count = 0
/100mL
Empty Total count Washer Total count < 50 /ML/ Once in a week
washed/ Discharge container
Rinsed Yeast & Mold < 25 /ML/ container
Container

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Treated Total count Total count < 25 Once in a week
Water After UV /ML

Coli form count Coli form count = 0 s

At proportioned /100mL
Total count Total count < 25/ML

Coli form Coli form count = 0 s

/100mL
Total count < 25
/ML
Sample type Test Sample point Specifications Minimum
/Attributes / Standards Frequency
CFU
Granular Total count From batch Total count < 200 Every 5th batch
Sucrose /10g
Yeast count Yeast count <
10 /10g
Mold count Mold count < 10 /
10g
Simple Yeast/mold count Before Filter < 5 per 5 ML Once in a week
Syrup After Filter < 5 per 5 ML Once in a week
Final syrup Yeast/mold count At the < 5 per 5 ML Once in a week
proportional
Beverage Yeast/mold count Sealed packages < 10 per 20 ML Once in a week

Final Rinse Yeast & Mold Filter Press < 10 /100ml Once in a week
Water from CIP Filler 6valves
Process Simple Syrup Once in a week
Total count Tank <25 /ml
Final Syrup
Tanks
Filler Valve /Snift Total Count Filler valve <10/valve Weekly
Yeast & Mold Filer valve <10/valve Weekly

At least weekly review microbiological data is done for trend and non-conforming
situations. When adverse situation occurs, initiate corrective action is taken. An
unsatisfactory microbiological test result indicates an effective cleaning and
sanitizing procedures and corrective action will be taken accordingly.

3.1.2. Control of Nonconforming Materials and Products

3.1.2.1. Nonconforming Material
Any ingredient, packaging material, intermediate product, or finished product that
do not meet the specification of The Coca-Cola-Company
3.1.2.2. Nonconforming Products
Products not meeting the specification of The Coca-Cola Company.

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The program covers the procedure to control all nonconforming incoming
materials, intermediate products, & final products. The program is followed to
prevent the use or distribution of nonconforming materials & products.

Nonconforming materials or products are not used for manufacturing or

packaging of the company products or are not distributed for customers.
Incoming materials, intermediate products or final products are tested and
verified in plant before released for use or distribution.

Materials & products that don’t meet the Coca-Cola Company specification are
segregated and stored in a separate area. And after different testing of the
quality of nonconforming materials or products it will be decided to reject the
nonconforming materials or products
Corrective action are taken to correct and eliminate the reoccurrence of non-
conformance, which are identified through different sources such as
internal/external audit, management review, and any employee request

3.1.3. Process Monitoring

This procedure applies for on line monitoring by taking samples at specified

interval of proportioning, carbonating and filling machine and applies to ensure
that all production processes continuously produce products with in company
specification.
3.1.3.1. Statistical Process Control (SPC)

SPC is used for on line process monitoring and control of proportioning,

carbonating and filling machines. It is a statistical tool used to monitor production
process.
3.1.3.2. Potential Capability Index (Cp)
A mathematical ratio of the specification range to the process precision (+ 3
Sample Standard Deviation). It only considers the process precision
3.1.3.3. Actual Capability Index (Cpk)
A reflection of both process yield and process precisions.

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3.1.3.4. Process Capability
The measured, inherent reproducibility of process.
3.1.3.5. Process Capability study
A systematic investigation to determine the ability of a process to meet stated
accuracy and precision requirements.

3.1.3.6. Sampling & Testing

Samples are taken from the filler for testing brix and carbonation of the product.
 If the brix and carbonation test result show that it is with in the Coca-Cola
Company specification limit, then the result is recorded on the daily
quality control report form and production will start.
 If specification limit don’t met, then the product is rejected from the
system and adjustment will be done on the machine. Then again sample
will be tasted after adjustment for brix & carbonation until the product
meets the company specification.
If the product meets the company specification production will continue and
samples will be analysed every thirty minutes to ensure the process is running
smoothly and to make sure that all products that do not meet company release
criteria does not released to the warehouse.
If there is any non-conformance in between the production run, then the line will
be stopped and non-conforming product will be isolate to investigate the problem
to remove reoccurrence. After analyzing the isolated product, necessary
measure will be taken.

3.1.3.7. Analyzing the Data

Sample average, sample standard deviation, and accuracy will be Calculated

using the formula listed below

Sample Average (X) = Xi / n, where X i = Individual values,

X= Sample average,  = Summation

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Sample Standard Deviation (s) = [n  X i 2 - ( X i) 2 /n (n-1)] ½
Where s = Sample standard deviation

Xi = individual values and n = number of samples.

Accuracy = X - Target where, X= sample average and Target = true or known

value.

The potential capability index (Cp) and Actual Capability Index (Cpk) are
calculated using the following formula.

Cp = (USL – LSL) / 6s where,

USL = Upper specification limit

LSL = lower specification Limit
S = Sample standard Deviation.
Cpk = (USL – X)/s or (X – LSL) / s where,
X = Sample Average
USL = Upper Specification limit
LSL = lower specification Limit
S = Sample standard Deviation

Use the lowest or smallest value of the two formulas to calculate the Cpk value.
Cpk = Lowest Value /3.

Evaluate the result against the standard

 The result will be evaluated against the standard to ensure that the
sample satisfies the company specification.

 Cp & Cpk should always be > 1.33 for the process capability to be
considered acceptable.

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  When the process is properly targeted, Cpk = Cp.When the process is not
targeted properly Cpk < Cp.
If the company process performance specifications are met, then they are
recorded serve as objective evidence.

If not met, the problem will be investigated and an appropriate corrective action
will be taken.
 For purchase of new equipment if they don’t meet company stated
accuracy and precision requirement the supplier will be contacted for
corrective action and redesign.
 When the existing processing equipment does not meet the company
performance specification a corrective action plan will be initiated to
address this concern. Specifically, the corrective action plan will ensure
that all products manufactured or tested with the equipment conform to
company release requirement.
If the result of the Corrective action plan indicates that the only long-term solution
is to purchase new equipment, but funds are not available, a problem interim
solution would be to increase inspection effort until capital becomes available.

3.1.4.Calibration

Testing and measuring equipments reliability measures are applied for the
Quality monitoring activities in the plant. In order to have accurate and reliable
measures for the different tests and analysis performed, Plant’s system requires
a strong calibration program that covers the following activities:
• Identification of testing and measuring equipment to be verified and
Calibrated with frequencies and responsibilities;
• Verification/re-calibration and calibration working instructions applied for
concerned equipment;
• Qualified person assigned for conducting calibration
• Handling of celebrants and reference standards.

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3.1.4.1. Identify Equipment
The followings are the processing and measuring equipment, which are
calibrated. Pressure gauge, balances, thermometers, turbidity meters, tanks, and
all other new measuring equipment used in the laboratories, water treatment,
syrup room, bottling hall, CO2 plant, air compressor, & boiler.

3.1.4.2. Calibration Internal

Calibration for measuring and processing equipment is done as per the

respective SOPs. Most of measuring and processing equipment are calibrated

against standard equipment with the accuracy of the manual recommendation.

This standard equipment is equipment, which are calibrated externally. Standard

equipments are used for measuring or processing, they are only use for

calibration purpose .Equipment which become out of accuracy range during

calibration are isolated from in use and leveled the status.

The current calibration status is labeled on the equipment or displayed near to

the equipment. The label indicate date of current calibration, the technician,
equipment identification No, and the next calibration date.

3.1.4.3. External Calibration

Calibration is also be done by the external authorized organization for verification

of measuring instrument. External bodies calibrate standard equipment used for

internal calibration of processing or measuring equipment and those, which

cannot be calibrated internally. The following measuring equipments are to be

calibrated by external authorized body, Dead weight tester, incubators, weighing

scales, thermometers, tanks, and flow meters.

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