S.M.V. BEVERAGES PVT.

LTD
ADITYAPUR – KANDRA ROAD,
JAMSHEDPUR (JHARKHAND)

A Project Report on

Submitted By :-
AISARYA DAS (13/FT/02)
INDEX
 CERTIFICATE
This is to certify that I, Aisarya Das has done this industrial training under the
guidance of training coordinator.

COMPANY’S NAME::S.M.V. BEVERAGES PVT. LTD

DATE:29.07.2016 Teacher’s Signature

 ACKNOWLEDGEMENT

With deep sense of regard, I take this opportunity of expressing my

profound gratitude and indebtance to Mr. S.N.S YADAV(G.M.)
and Mr. P. Kumar, C.E.O. PepsiCo (S.M.V. Beverages) for
accepting my request for providing me the opportunity for
Summer Training.
I am also thankful to Mr. C.K. Dubey (Q.C.M. ) and all staff
members for providing me invaluable suggestion, guidance and
encouragement. Without their support and encouragement, it would
not have been possible for me to complete this task.
I would specially like to thanks Mr. AnandSharma . For their
special attention and guidance which helped me to understand the
processes and majors applied in the industry.
My sincere thanks also goes to Mr C.D. Mishra for helping me in
completing this project.
At last I want to thank all known and unknown hands that directly
& indirectly motivated me to complete this project.

Aisarya Das
NON-CARBONATED BEVERAGE
CONTENT
 INTRODUCTION
Non-carbonated beverages are the beverages that do not have added carbon dioxide. Because
of this they lack the protection against spoilage offered by carbonation and are typically
pasteurized either in bulk or by continuous flash pasteurization prior to filling or in the bottle.
Fueled by the perception that non-carbonated beverages are healthier than carbonated
beverages the market is enjoying the recent growth and most traditional soft-drink producers
are diversifying their offering to include noncarbonated beverages.

Examples: Water,Milk,Wine,Tea,Coffee.

The non carbonated line in SMV Beverages only produces SLICEwhich is a line of fruit-
flavoured soft drinks introduced in 1984.

Product Name: SLICE

Type: Flavoured Soft Drink

Manufacturer: PepsiCo

Country of Origin: United States

Introduced: 1984

Varieties of Slices includes mango, lemon-lime, apple, fruit punch, grape, passionfruit, peach,
Mandarin orange, pineapple, strawberry etc. But the non carbonation line in SMV produces
only the mango flavoured SLICE.

The two process lines for SLICE includes :

 GRB(Glass Returnable Bottle) Line

 PET(Polyethylene Terephthalate) Line
 BEVERAGE MAKING
5 step CIP Process

Unit size water is taken in a tank

Temperature of water is raised to 65 degree Celsius

Sugar Dumping(Calculated amount)

Addition of Activated Carbon (Contact Time 15 minutes)

Temperature rise to 80 degree Celsius. Addition of Celite in Precoating

tank.

Precoating in Filter Press

Recirculation

Temperature reduction to less than 25 degree Celsius using Plate Heat

Exchanger
 Transfer to simple syrup holding tank Check Brix

Blending Process (salt part, pulp, flavor, additives, chemicals)

Disc Filter

Magnetic Filter

Double Stage Homogenisation

Final beverage in Finished Syrup tank Check Brix, TA, pH

Pasteurization at 90-95 degree Celsius for 35 seconds

Balance Tank
 Hot filling in washed glass bottles at 85-90 degree Celsius

Crowning

Bottle Inspection

Date Coding

Encasing

BOTTLE WASHING PROCESS

 Market return bottles

Uncasing

Inspection of bottles

Bottles are fed in washer

Pre-soak

Main-soak

Mex power

Hydro-soak

Horolith&Ferrisol

Pre-final

Final
 Bottles in feed: This is the first chamber of the bottle washing machine. First the
bottles are send inside the chamber.
 Residual draining- This is the next stage where any residue that might be present
inside the bottles is drained by inverting the bottles.
 Pre rinse jet- Here bottles are washed by treated soft water.
 Pre soak- In this region bottles are washed by treated water, which has 2-2.5% of
caustic for washing and sanitizing purpose. This region should not maintain high
temperature and high caustic percentage. The temperature range is 50-55 °C.
 Pre heat rinse- In this region bottles are rinsed with hot water for the removal of
caustic and also for minimizing the microbial contamination.
 Hot caustic tank- After pre heat rinse the bottles come into this tank where the
temperature of the caustic solution is high and the percentage of caustic solution is
maintained higher than 2.5-3% in the presoak region. The temperature range is 74
to79°C.
 Hot caustic soak with high pressure jetting- In this region the bottles are washed
with high pressure jetting by which if any foreign matter is present inside the
bottle, may come out.
 Warm water jetting- In this region the bottles are washed with warm water to low
down the temperature of the bottles for avoiding the breakage.
 Caustic carryover water jetting- In this region bottles are jetted for avoiding the
carryover of caustic solution.
 Warm water jetting- This time the bottles are jetted with warm water.
 Warm water soak- Here bottles are with warm water soak that have some
percentage of caustic.
 Cold water jetting- This time bottles are just washed with cold water to maintain
the temperature of the bottles.
 Fresh water jetting- This is the last chamber of bottle washing machine. In this
region the bottles are jetted with fresh water. The bottles that come out from the
above process are fully sanitized. The above process takes around 22-33 min to
clean a bottle.
TESTS IN NON-CARBONATED BEVERAGE
1. CAUSTIC STRENGTH AND CARBONATE IN PRE-SOAK&
MAIN SOAK
 10ml of washing water from Pre-soak is taken as sample.
 3-4 drops of phenolpthaleinindicator is added. Colour turns pink.
 It is then titrated with 2.5(N) H2SO4.
 Colour changes from pink to colourless. The titre value is noted and it is
termed as ‘P’ value.
 Methyl Purple is added. Colour turns green.
 It is then titrated with 2.5(N) H2SO4. Colour turns purple.
 The titre value is noted which is termed as ‘M’ value.
% of Caustic = (2P-M)

% of Carbonate=2(M-P)*0.53

2. TESTS FOR CHECKING PROPER BOTTLE WASHING

a) Caustic carryover
 Empty washed bottles are collected from bottle washer as samples.
 Phenolphthalein is added in the empty bottle.
 If colour turns pink it indicates caustic carry over.
 The bottle is rejected.
b) Methylene Blue Test to check mold
 Empty washed bottles are collected from bottle washer as samples.
 100ml of Methylene Blue is added in the bottle.
 The bottle is washed with water and checked for blue patches.
 Presence of blue patches indicates presence of moulds and the bottle is
rejected.
3. TESTS FOR READY SYRUP
a. pH
 Sample is taken in beaker.
 The pH probe is washed using distilled water and dried using tissue
paper.
 The probe is placed in water sample and the reading shown in the display
of the pH meter is noted.
b. Brix
 The refractometer is washed with distilled water.
 Some amount of sample is taken.
 The reading is checked in the refractometer.
c. Titrable Acidity
 100ml of sample is taken in a beaker.
 It is placed in magnetic stirrer which shows the pH 3.14 at 26.8oC.
 It is titrated with 0.1(N) NaOH.
 The titration is continued until the pH becomes 8.75 which is displayed in
the screen of the magnetic stirrer.
 The burrette is noted which is the titre value.
 The titre value is multiplied with 1.004 to get the titrable acidity.

Titrable Acidity= Titre Value *1.004

4. TESTS FOR BOTTLE CONTAINING FINISHED

PRODUCT‘SLICE’
I. Crimping Check
 Glass bottles are taken.
 A crimping checking bar is there which has holes of different diameters.
 The desired crown should pass through 1.35mm and not through 1.25mm.
 Then crimping is perfect.
 If doesn’t pass through 1.35 mm then under crimping.
 If passes through 1.25mm then over crimping.
 II. TEMPERATURE TESTING
 Glass bottles are taken.
 IR gun is taken and the bottle temperature is read by the IR gun.
 The temperature is taken as bottle temperature.

MICROBIOLOGICAL TESTS DONE FOR NON-

CARBONATED AND ITS PLANT
ENVIRONMENT
I. TESTS FOR FINAL SYRUP
 Media : Orange Serum Agar
 Identifies : Aciduric Bacteria
 Method : Pour Plate Technique
 10ml of slice sample is taken in a petri plate containing 50-55ml of
media.
 The petri plate is rotated clockwise and then anti-clockwise.
 It is kept for some time for solidification.
 The petri plate is incubated at 30oC for 48 hrs.
 The microbial count is checked.

 Media : Potato Dextrose Agar

 Identifies : Yeast &Mould
 Method : Pour Plate Technique
 10ml of Slice sample is taken in a petri plate containing 50-55ml of
media.
 The Petri plate is rotated clockwise and then anti-clockwise.
 It is kept for some time for solidification
 The petri plate is incubated at 25oC for 72 hrs and then 128 hrs.
 The presence of yeast and mould is checked after incubation.
II. TESTS FOR PLANT ENVIRONMENT
 Media : Potato Dextrose Agar
 Identifies : Yeast &Mould
 Method : Using Air Sampler
 10ml of media is added in 90mm petri dishes.
 It is kept for sometime at rest for solidification of agar.
 The petri plate is put into a air-sampler which absorbs 100ltr of air from a
particular plant environment.
 The petri plate is incubated at 25oC for 72 hrs and then for 128 hrs.
 The presence of yeast and mould is checked in the petri plate.

III. TESTS FOR SIMPLE SYRUP

 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold
 Method : Membrane filtration& Pour Plate Technique
 10ml of simple syrup is taken in a beaker.
 90ml of peptone water or distilled water is added in the beaker and mixed
well.
 It is then filtered by membrane filtration technique.
 Additional 20ml of distilled water is added to it.
 It is again filtered by membrane filtration technique.
 The syrup sample is plated in Mgreen Yeast & mold broth media and
incubated at 25oC for 72hrs and then for 120hrs.
 After incubation the presence of yeast & mold is checked which should
be zero.

IV. TESTS FOR MACHINERY

 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold, Aciduric Bacteria
 Method : Membrane filtration & Pour Plate Technique
 0.1% of peptone water is added in swab tube which has the swab bud
dispersed in it.
 The dipped swab bud is rubbed in 2 square inches area and again dipped
in peptone water.
 The peptone water is filtered using membrane filtration technique.
 47mm petri plate is taken and absorbent pad is placed in it.
 2ml of thebroth media is added in the petri plate.
 The filter paper from the membrane filter is placed on the petri plate by
using forceps.
 The petri plates are incubated at 25oC for 72 hrs and then for 120 hrs.
 After incubation the count of yeast & mold and aciduric bacteria is
checked.
CARBONATED BEVERAGE
CONTENT

INTRODUCTION
Carbonated beveragesare the beverages that has dissolved carbon dioxide in it, most often to
improve the taste and texture. The presence of this gas creates bubbles and fizzing in the
liquid. Carbonation can occur naturally underground or artificially, through pressurizing.

Examples of carbonated beverages include spring water, beer and soda.

Beverages are artificially carbonated when carbon dioxide is dissolved into the liquid under
high pressure. When that pressure is released, small gas bubbles develop. Carbonation can
also occur naturally when carbon dioxide gas is dissolved into a liquid, such as spring water,
which absorbs CO2 underground.

Beverages are carbonated for various reasons. Many people find the fizzy sensation to be
pleasant and like the slightly different taste that carbon dioxide provides. Carbonated
beverages, particularly naturally carbonated spring water ewre once thought to be health
tonics, and the effervescence can help soothe an upset stomach. The carbon dioxide in a
carbonated beverage also causes people to burp after they drink it, because the gas is released
after being ingested into the body

The carbonated line in SMV Beverages produces Pepsi, Mountain Dew, 7up, Mirinda,
Lehar Evervess(soda water).

Product Name :PEPSI, MOUNTAIN DEW, 7UP, MIRINDA

Type :Carbonated Soft Drink

Manufacturer :PepsiCo

Country of Origin :United States

Introduced :1893
 BEVERAGE MAKING

3 step CIP process

Sugar dumping in hopper

Sugar conveyer vacuum Dust part out

Raw syrup tank Hot water(60oC) addition

Temperature rise to 65oC

Addition of Activated Carbon(Contact time 15 minutes)

Temperature rise to 80oC and addition of Filter Aid(Celite) in

Pre-coating tank

Precoating in Filter Press

 Recirculation

Temperature reduction to less than 25 degree Celsius using Plate

Heat Exchanger

Transfer to ready syrup tank

Extra Sugar dosing by calculating to prevent sugar loss

Check Brix

Concentrate dosing in ready syrup tank

Mixing of syrup & water in the ratio of 1:5 along with CO2
inTrimatic Machine
 Cooling at 2-3oC in Trimatic Machine

Filling in Filling in
previously previously
washed glass washed PET
bottles bottles

Capping

Crimping

Warmer

Date coding
Inspection

Encasing in machine Labelling

Packaging
 BOTTLE WASHING
 GLASS RETURNABLE BOTTLE(GRB) LINE

Market returned glass bottles

Uncasing

Bottles are fed in washer

Pre-soak

Main-soak

Mex power

Hydro-soak

Ferrisol, Horolith

Pre-final

Final
 Bottles in feed: This the first chamber of the bottle washing machine. First the
bottles are send inside the chamber.
 Residual draining- This is the next stage where any residue that might be present
inside the bottles is drained by inverting the bottles.
 Pre rinse jet- Here bottles are washed by treated soft water.
 Pre soak- In this region bottles are washed by treated water, which has 1.5% of
caustic for washing and sanitizing purpose. This region should not maintain the
high temperature and high caustic percentage. The temperature range is 50-55 °C.
 Pre heat rinse- In this region bottles are rinsed with hot water for the removal of
caustic and also for minimizing the microbial contamination.
 Hot caustic tank- After pre heat rinse the bottles come into this tank where the
temperature of the caustic solution is high and the percentage of caustic solution is
maintained higher than 2-2.5% in the presoak region. The temperature range is 72
to76 °C.
 Hot caustic soak with high pressure jetting- In this region the bottles are washed
with high pressure jetting by which if any foreign matter is present inside the
bottle, may come out.
 Warm caustic tank- In this tank the temperature is kept lower than the hot caustic
tank.
 Warm caustic tank with high pressure jetting- In this region the bottles are again
jetted with pressure to remove any foreign matter inside the bottles.
 Warm water jetting- In this region the bottles are washed with warm water to low
down the temperature of the bottles for avoiding the breakage.
 Caustic carryover water jetting- In this region bottles are jetted for avoiding the
carryover of caustic solution.
 Warm water jetting- This time the bottles are jetted with warm water.
 Warm water soak- here bottles are with warm water soak that have some
percentage of caustic.
 Cold water jetting- This time bottles are just washed with cold water to maintain
the temperature of the bottles.
 Fresh water jetting- This is the last chamber of bottle washing machine. In this
region the bottles are jetted with fresh water. The bottles that come out from the
above process are fully sanitized. The above process takes around 22-33 min to
clean a bottle.
BOTTLE BLOWING PROCESS
BOTTLE BLOWING
Preform PROCESS
from other manufacturing unit

Blow moulding machine

Fully blown bottles in desired shapes and sizes

Passes through conveyer by HEPA filter

Bottle inversion

Rinsing of bottles by jet washer

Washed PET bottles pass to the bottle

filling line
TESTS IN CARBONATED BEVERAGE
1. CAUSTIC STRENGTH AND CARBONATE IN PRE-SOAK &
MAIN SOAK
 10ml of washing water from Pre-soak is taken as sample.
 3-4 drops of phenolpthalein indicator is added. Colour turns pink.
 It is then titrated with 2.5(N) H2SO4.
 Colour changes from pink to colourless. The titre value is noted and it is
termed as ‘P’ value.
 Methyl Purple is added. Colour turns green.
 It is then titrated with 2.5(N) H2SO4. Colour turns purple.
 The titre value is noted which is termed as ‘M’ value.
% of Caustic = (2P-M)

% of Carbonate=2(M-P)*0.53

2. TESTS FOR CHECKING PROPER BOTTLE WASHING

c) Caustic carryover
 Empty washed bottles are collected from bottle washer as samples.
 Phenolphthalein is added in the empty bottle.
 If colour turns pink it indicates caustic carry over.
 The bottle is rejected.
d) Methylene Blue Test to check mold
 Empty washed bottles are collected from bottle washer as samples.
 100ml of Methylene Blue is added in the bottle.
 The bottle is washed with water and checked for blue patches.
 Presence of blue patches indicates presence of moulds and the bottle is
rejected.
3. TESTS FOR READY SYRUP
d. pH
 Sample is taken in beaker.
 The pH probe is washed using distilled water and dried using tissue
paper.
 The probe is placed in water sample and the reading shown in the display
of the pH meter is noted.
e. Brix
 The refractometer is washed with distilled water.
 Some amount of sample is taken.
 The reading is checked in the refractometer.
f. Titrable Acidity
 100ml of sample is taken in a beaker.
 It is placed in magnetic stirrer which shows the pH 3.14 at 26.8oC.
 It is titrated with 0.1(N) NaOH.
 The titration is continued until the pH becomes 8.75 which is displayed in
the screen of the magnetic stirrer.
 The burrette is noted which is the titre value.
 The titre value is multiplied with 1.004 to get the titrable acidity.

Titrable Acidity= Titre Value *1.004

4. TESTS FOR BOTTLE CONTAINING FINISHED PRODUCT

‘SLICE’
I. CRIMPING CHECK
 Glass bottles are taken.
 A crimping checking bar is there which has holes of different diameters.
 The desired crown should pass through 1.35mm and not through 1.25mm.
 Then crimping is perfect.
 If doesn’t pass through 1.35 mm then under crimping.
 If passes through 1.25mm then over crimping.
 II. TEMPERATURE TESTING(GRB & PET BOTTLES)
 Glass bottles are taken.
 IR gun is taken and the bottle temperature is read by the IR gun.
 The temperature is taken as bottle temperature.

III. PRESENCE OF AMOUNT OF GAS, PRESSURE

TEMPERATURE
 PET bottles are taken and placed in a gas volume shaker.
 Pressure is applied so that the pincer pinces the bottle cap.
 The bottle is well placed in the shaker and machine is started.
 After sometime when the machine stops the amount of gas present is
shown in the meter. Also the temperature and pressure of the beverage
is displayed.
IV. INVERTED BRIX
 100 ml of sample is taken in a beaker.
 It is degassed in the degassing unit(1.5 minutes for PET bottles and
1 minute for GRB bottles).
 30ml of the degassed sample is taken in a reagent flask.
 It is wrapped in aluminium foil and placed in a water bath at 98oC
for 1hr.
 The refractometer is washed with distilled water.
 Some amount of sample is taken.
 The reading is checked in the refractometer.
 MICROBIOLOGICAL TESTS DONE FOR
CARBONATED AND ITS PLANT
ENVIRONMENT
A. TESTS FOR SIMPLE SYRUP
 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold
 Method : Membrane filtration& Pour Plate Technique
 10ml of simple syrup is taken in a beaker.
 90ml of peptone water or distilled water is added in the beaker and mixed
well.
 It is then filtered by membrane filtration technique.
 Additional 20ml of distilled water is added to it.
 It is again filtered by membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is
placed in it using sterile forceps.
 2ml of the syrup sample is plated in Mgreen Yeast & Mold broth media
in the petri plate and filter paper from membrane filter is added and
incubated at 25oC for 72hrs and then for 120hrs.
 After incubation the presence of yeast & mold is checked which should
be zero.

B. TESTS FOR FINISHED SYRUP

 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold
 Method : Membrane filtration& Pour Plate Technique
 100ml of finished syrup is taken in a beaker.
 It is then filtered by membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is
placed in it using sterile forceps.
 2ml of the syrup sample is plated in Mgreen Yeast & mold broth media in
the petri plate and filter paper from membrane filter is added and
incubated at 25oC for 72hrs and then for 120hrs.
 After incubation the presence of yeast & mold is checked which should
be zero.
C. TESTS FOR FINISHED PRODUCT
 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold
 Method : Membrane filtration& Pour Plate Technique
 100ml of finished syrup is taken in a beaker.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is
placed in it using sterile forceps.
 The syrup sample is plated in Mgreen Yeast & mold broth media in the
petri plate and incubated at 25oC for 72hrs and then for 120hrs.
 After incubation the presence of yeast & mold is checked which should
be zero.

D. TESTS FOR WATER SAMPLES FROM :

 Before 5 micron & after 5 micron cartridge
 Before UV & after UV
 Permeate
 Treated water before and after UV
 Soft water before and after UV
 Warmer
 Media : Mendo agar
 Identifies : Coliform
 Method : Membrane filtration& Pour Plate Technique
 100ml of water sample is taken in a beaker.
 It is then filtered by membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is
placed in it using sterile forceps.
 The water sample is plated in Mendo agar media in the petri plate and
filter paper from the membrane filter is added and incubated at 35oC for
24hrs.
 After incubation the coliform count is done.
  Media : MTGE
 Identifies : Total Bacterial Count
 Method : Membrane filtration& Pour Plate Technique
 100ml of water sample is taken in a beaker.
 It is then filtered by membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is
placed in it using sterile forceps.
 The water sample is plated in MTGE media in the petri plate and filter
paper from the membrane filter is added and incubated at 35oC for 48hrs.
 After incubation the total bacterial count is done.
E. TESTS FOR CROWN & CLOSURE :
 Media 1 : MTGE
 Identifies : Total Bacterial Count
 Method : Membrane filtration& Pour Plate Technique
 Cap or closure is taken and dipped in Isopropyl alcohol
 Using forceps it is placed in whirl pack bags.
 100ml peptone water or autoclaved distilled water is added into it and shaked well.
 The water is filteredby membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is placed in it
using sterile forceps.
 The water sample is plated in 2ml media in the petri plate and filter paper from the
membrane filter is added and incubated at 35oC for 48hrs.
 After incubation the total bacterial count is done.
 Media : Mgreen Yeast & Mold broth
 Identifies : Yeast & Mold
 Method : Membrane filtration & Pour Plate Technique
 Cap or closure is taken and dipped in Isopropyl alcohol
 Using forceps it is placed in whirl pack bags.
 100ml peptone water or autoclaved distilled water is added into it and shaked
well.
 The water is filtered by membrane filtration technique.
 A sterile 47 mm sterile petri plate is taken and a sterile absorbent pad is placed
in it using sterile forceps.
 The water sample is plated in 2ml media in the petri plate and filter paper from
the membrane filter is added and incubated at 25oC for 72hrs and then for
120hrs.
 After incubation the presence of yeast & mold is checked.
 SODA WATER
Carbonated wateralso known as club soda, soda water, sparkling water, seltzer water or fizzy
water is water into which carbon dioxide gas under pressure has been dissolved. Some of
these have additives such as sodium, but seltzer water is almost always composed of water
and carbon dioxide with no other additives. This process known as Carbonation is a process
that causes the water to become effervescent. Most carbonated water is sold in ready to drink
bottles as mineral water and carbonated beverages such as soft drinks.

Soda water may be identical to plain carbonated water or it may contain a small amount of
table salt, sodium citrate, sodium bicarbonate, potassium bicarbonate, potassium citrate,
potassium sulphate or disodium sulphate, depending on the bottler.

Water is chilled optimally to just above freezing , in order to permit the maximum amount of
carbon dioxide to dissolve in it. Higher gas pressure and lower temperature can cause more
gas to dissolve in the liquid. When the temperature is raised or the pressure is reduced, carbon
dioxide comes out of the solution, in the form of bubbles. This is known as effervescence.

Product Name : LEHAR EVERVESS

Type :Carbonated Water

Manufacturer :PepsiCo

Country of Origin :United States

SODA WATER MAKING

Treated water from RO

Plate heat exchanger(PHE)

 Water tank CO2 addition

Proper mixing of CO2

Plate heat exchanger(PHE)

Storage tank

Filler

Filling in washed PET bottles

Capping

Conveyer
 Inspection

Warmer

Drier

Labelling

Date coding

Inspection

Case packer

Packaging in cartoon box

 WATER
Water is a transparent fluid which forms the world’s streams, lakes, oceans, and rain, and is
the major constituent of the fluids of organisms. Water is a liquid at standard ambient
temperatureand pressure, but it often co-exists on Earth with its solid state, ice; and gaseous
state, steam(water vapour). It also exists as snow, fog, dew and cloud.

Water is tasteless and colourless. The intrinsic colour of water and ice is a very slight blue
hue, although both appearcolourless in small quantities. Water is transparent in the visible
electromagnetic spectrum. Thus aquatic plants can live in water because sunlight can reach
them. Infrared light is strongly absorbed by the hydrogen oxygen or OH bonds.

Many people & beverage industry depend throughout the world on underground sources of
drinking water and potable water. Water is major constituent of beverage or soft drinks. In
soft drink industry almost 99% water is used for making soft drinks and cola and non cola
beverage. Untreated ground water is mostly pure and cleaned than any surface water.The
PepsiCo India Holdings Pvt. Ltd. Jainpur has it own source of water supply.

This plant is also using the ground water by using bore well. However, this water is now a
days polluted by different types of human activities like sewage disposal in unscientific ways,
refuse dumps from yard manures , pesticide and chemical fertilizer contamination, disposal of
hospital water, industrial effluents discharge etc. E. coli and other bacterial contamination are
being reported from ground water sample of different regions. Heavy metals are also present
in different ground water sample collected from industrial region of India.

Therefore water treatment is necessary for the removal of impurities, micro organism and
heavy metals which cause disease and also alter the product quality of beverage industries.
There are various methods of water treatment like membrane filtration, reverse osmosis, nano
filtration, and ultra filtration. While coagulation is widely used for the treatment of water.

The whole processing line in SMV Beverages uses three types of water mainly :

1) RAW WATER
2) SOFT WATER
3) TREATED WATER
 Coagulated water
 Pre RO water
 RAW WATER
Raw wateris natural water found in the environment and has not been treated, nor have any
minerals, ions, particles or living organisms removed. Raw water includes rain water, ground
water, water from infiltration wells, and water from bodies like lakes and rivers. The
characteristics of raw water include physical ones, such as taste, temperature, or turbidity,
chemical ones such as hardness, acidity/alkalinity and ion content and biological ones such
as organism presence. These characteristics can vary greatly depending on environmental
conditions. Pollution can also effect raw water content.

Contaminants usually make raw water unsafe for drinking by humans without treatment. The
composition of raw water is naturally variable, but commonly contains one or more of the
following significant contaminants, in the form of dissolved ions, particles and living
organisms.

 Minerals like carbonates of calcium and magnesium

 Clay and silt particles.
 Dissolved air specially oxygen
 Salt
 Microorganisms

TESTS FOR RAW WATER

 Total Alkalinity
 pH
 Total Hardness
 Total Dissolved Solids
 Free Chlorine
 Iron
 Manganese
 Turbidity
 SOFT WATER
Soft wateris the surface water that contains low concentrations of ions and in particular is low
in ions of calcium and magnesium. Soft water naturally occurs where rainfall and the
drainage basin of rivers are formed of hard, impervious and calcium poor rocks. Because soft
water has few calcium ions, there is no inhibition of the action of soaps and no soap scum is
formed in normal washing. Similarly soft water produces no calcium deposits in water
heating systems. Water that is not soft is refered to as hard water.

Soft water forms lather with soap and does not form scum in such amount. It contains the
normal salts required by the body. Soft water mostly comes from peat or igneous rock
sources, such as granite but may also come from sandstone sources, since those sedimentary
rocks are usually low in calcium and magnesium.

Water softening is the process of removal of calcium, magnesium and certain other metal
cations in hard water. The resulting soft water is more compatible with soap and extends the
lifetime of plumbing. Water softening is usually achieved using lime softening or ion-
exchange resins.

TESTS FOR SOFT WATER

 pH
 Total Dissolved Solids
 Total Hardness
 Chlorine content

SOFT WATER PROCESSING

Raw water storage tank

Sand filter

Activated carbon tank 1

 Activated carbon tank 2

Softener

Beverage plant
Recirculation

TREATED WATER
Treated water is the water that is produced from water treatment process that makes water
more acceptable for a specific end use. Water treatment removes contaminants or reduces
their concentration so that water becomes fit for its desired end-use.Treatment for drinking
water production includes the removal of contaminants from raw water to produce water that
is pure enough for human consumption without any short term or long term risk of any
adverse health effect..

The treated water used in SMV Beverages is mainly of two types:

 Coagulated water
 Pre-RO water

TESTS FOR TREATED WATER

 Total Alkalinity
 pH
 Total Hardness
 Total Dissolved Solids
 Total Chlorine
 Iron
 Manganese
 Turbidity
 COAGULATED WATER
Coagulated water is the water that is produced by coagulation in which a coagulant is added
to water to destabilize the colloidal suspensions. In a colloidal suspension , particles will
settle very slowly or not at all because the colloidal particles carry surface electrical charges
that mutually repel each other. A coagulant (typically a metal salt) with the opposite charge is
added to the water to overcome the repulsive charge and destabilize the suspension.

Lime FeSO4Chlorine

Raw water

Mixing tank Reaction

tank

Sand Intermediate
Activated Carbon Filter 1
filter tank

Polisher UV
Activated Carbon Filter 2

Treated water /
Coagulated water
 Procedure-

1. Coagulant, bleaching solution and lime mix together in the reaction tank and cause
almost all of the raw water alkalinity(usually present as bicarbonate) to be converted
to carbonate, which precipitates out of the solution and settle to the bottom of the
tank.
2. At the same time, a floc is formed that in traps calcium carbonate, suspended solids,
oxidized iron and manganese and many other contaminants.
3. This floc grow in size, become heavy and help to alkalinity and impurities to settles
more quickly to the bottom of the reactor (this forms the sludge).
4. If every thing is sized and operated correctly the treated water should easily reach 35
to 40 mg/l alkalinity and be free of odor, color, turbidity, metals and many organics.
5. The water from reaction tank is stored in intermediate tank.
6. In sand filter gravels are present from larger to smaller size as we upwards in the tank.
Sand present at the topmost layer of these particles act as filtering material. All the
large size particles get stuck in the particles.
7. Activated Carbon present in the Activated Carbon tank 1 & 2 extracts off chlorine,
colour, odour.
8. In 5 micron polisher, the water enters and the particles with more than 5 micron size
does not enter the polisher and the water gets purified.
9. In the U.V. the water gets purified from all types of microorganisms.
10. The water coming out from UV is called Treated Water or Coagulated Water.

Reactions:

 Ferric sulfate or ferrous sulfate +chlorine

Ferrous sulfate +Chlorine forms ferric sulfate

Ferrous sulfate + lime forms ferric hydroxide

 Ferric hydroxide diminishes contaminates, color, turbidity, organic

matter, microbe sink to bottom charge neutralization.
BACK WASHING

Back washing is the process by which the sand filter tank are washed. Back washing takes
place after every 24 hrs. In this process washing takes place in the sand filter tank from
bottom to top in an upward direction.
 PRE-RO WATER
Pre-RO water normally means the water before Reverse Osmosis treatment. Reverse osmosis
is a technology that is used to remove a large majority of contaminants from water by
pushing the water under pressure through a semi-permeable membrane. A semi-permeable
membrane is a membrane that will allow some atoms or molecules to pass but not
others.Reverse Osmosis is the process of Osmosis in reverse. Whereas osmosis occurs
naturally without energy required, to reverse the process of osmosis. A reverse osmosis
membrane is a semi-permeable membrane that allows the passage of water molecules but not
the majority of dissolved salts, organics, bacteria and pyrogens.

PROCESSING OF PRE-RO WATER

Supply water

Raw water storage tank

Sand filter

Sand filter storage tank

Activated carbon filter 1

Contact time 15
minutes
Activated carbon filter 2
 Anti-scaling agent
&NaOH

5 micron cartridge

UV

RO

Reject Permeate

Recovery Storage tank

Recirculation tank

Non-carbonated beverage Post-RO

 TESTS FOR TREATED WATER
 Raw water
 Free chlorine
 pH
 Total Dissolved Solids
 Total Alkalinity
 Iron
 Manganese
 Turbidity
 Sand filter
 Free chlorine
 ACF 1
 Total Chlorine
 SDI(<5)
 ACF 2
 Total Chlorine
 SDI(<5)
 5 micron polisher
 SDI
 Feed water
 Total Dissolved Solids
 pH
 Iron
 Turbidity
 Manganese
 Permeate water
 Total Dissolved Solids
 pH
 Treated water
 Clarity through 0.45 micron
 pH testing
 Sample is taken in beaker.
 The pH probe is washed using distilled water and dried using tissue
paper.
 The probe is placed in water sample and the reading shown in the display
of the pH meter is noted.
 Chlorine testing
 5ml of water sample is taken in small tubes .
 Chlorine pouches(Free chlorine for Raw water and Total chlorine for
Soft water & Treated water) are added in the tube.
 Pink colour is formed if chlorine is present in the sample.
 Another tube is taken consisting of only water sample which is
considered as blank.
 The tube is placed in the Colorimeter and the reading which is displayed
shows the amount of chlorine present in water sample taken.

 Total Dissolved Solids by Conductivitymeter

 Sample is taken in a beaker.
 The conductivity probe is washed using distilled water and dried using
tissue paper.
 The probe is placed in water sample and the reading shown in the display
of the conductivity meter is noted.

Total Dissolved Solids = Titre Value * Calibration Factor

 Total Alkalinity
 100 ml of the sample is taken in a beaker.
 3-4 drops of T solution.is added.
 Methyl purple is added and it is titrated with (N/50) H2SO4.
 The titration is continued until the colour changes from green to purple.
 The titre value is noted.
 The titre value is multiplied with calibration factor.

 Total Hardness
 100 ml of the sample is taken in a beaker.
 3-4 drops of NH3 buffer is added in the water sample.
 A pinch of Hardness Indicator is added.
 It is titrated with 0.02N EDTA.
  Colour changes from red to purple to blue.
 The titre value is noted which gives the total hardness.

 Iron testing
 10ml of water sample is taken in small tubes .
 Indicator pouches are added in the tube.
 Orange colour is formed if iron is present in the sample.
 Another tube is taken consisting of only water sample which is
considered as blank.
 The tube is placed in the Ferroverand the reading which is displayed
shows the amount of iron present in water sample taken.

 Manganese testing
 10ml of water sample is taken in small tubes .
 Indicator pouches are added in the tube.
 Another tube is taken consisting of only water sample which is
considered as blank.
 The tube is placed in the Manganese LR and the reading which is
displayed shows the amount of manganese present in water sample
taken.

 Turbidity testing
 10ml of water sample is taken in small tubes .
 Indicator pouches are added in the tube.
 Another tube is taken consisting of only water sample which is
considered as blank.
 The tube is placed in the Turbidity meter and the reading which is
displayed shows the amount of turbidity present in water sample taken.
 MICROBIOLOGICAL TESTS DONE FOR
WATER
PRE-RO line
 Media
 Mendo broth for Total Coliform
 Base agar for Pseudomonas
 MTGE for Total BacterialCount
 Method
 Membrane filtration technique

Raw tank

Sample from inlet Sand filter Sample from outlet

Activated Carbon Tank

Sample from outlet
Sample from inlet 1

Activated Carbon Tank 2

Sample from inlet Sample from outlet
Sample from inlet 5 micron Sample from outlet

UV Sample from outlet

Sample from inlet

Sample from inlet Permeate Sample from outlet

Treated water Sample from outlet

 100ml of water sample is taken in a beaker.

 It is then filtered by membrane filtration technique.
 A sterile 47 mm petri plate is taken and a sterile absorbent pad is placed in it using
sterile forceps.
 The water sample is plated in required media in the petri plate and filter paper from
the membrane filter is added and incubated at required temperature and time.
 After incubation the counts are checked.
PACKAGED DRINKING WATER
CONTENT
 INTRODUCTION
Packaged drinking water also known as bottled water, distilled water, mineral water is the
water that is packaged in plastic or glass bottles. Packaged drinking water does not
necessarily be carbonated water.

The packaged drinking water processing line in SMV Beverages produces

AQUAFINAPURE WATER. It is the primary unflavoured product produced under the
Aquafina brand, derived from local municipal tap water sources and goes through a
purification process that incorporates reverse osmosis, ultraviolet and ozone sterilization.

Flavoured variations are also produced under the Aquafina brand name all which are labelled
as containing no calories and no carbohydrates.

Aquafina goes through a five step purification process to give consumers pure water and
perfect taste.

Product Name :AQUAFINA

Type :Packaged Drinking Water

Manufacturer: PepsiCo

Country of Origin: United States

Introduced: 1994

WATER PROCESSING

Water from Pre-RO

pH maintaining
Anti-scaling agent

5 micron cartridge
 UV

Reject RO tube Permeate

1 micron cartridge

Ozonator

Ozone analyser

Ozone contact tank

Ozone analyser

NO If ozone
level >(0.2-
0.4ppm)
 YES

Filler

Capping

Labelling

Date coding

Packaging

Secondary coding

Packaging