A

PROJECT REPORT ON IN-PLANT TRAINING

AT

ASSOCIATED BLENDERS PVT. LTD., PUNE.

SUBMITTED FOR

THE PARTIAL FULFILMENT OF THE REQUIREMENT OF THE

DEGREE OF BACHELOR OF TECHNOLOGY

IN

FOOD TECHNOLOGY

SUBMITTED BY

SUTAR AJINKYA ANIL

(FTL-68/2014)

SUBMITTED TO

MAEER′s

MIT COLLEGE OF FOOD TECHNOLOGY, PUNE

AFFILIATED TO

MAHATMA PHULE KRISHI VIDYAPEETH, RAHURI.

2017-2018
 ACKNOWLEDGEMENT

I would like to thanks respected Mr. Murali Ramachandra (Director &

Production Head) of “Associated Blenders Pvt. Ltd.Pune.”

I would also especially thanks to Mr. Sachin Shelake (I/c Quality control Lab)
and Mr. Milind Dhayagude(I/c, Accounts Department) at “Associated Blenders
Pvt Ltd” Pune.

I would also especially thanks to all the Workers, Operators and all known
persons who co-operated and guided to me directly or indirectly during our
in-plant training at “Associated Blenders Pvt. Ltd” Pune.

I would also express my thanks to Dr.V.N. Pawar, Principal, MIT College of

Food Technology, Loni-Kalbhor, Pune for permitting me to do my in-plant
training in Associated Blenders Pvt. Ltd.Pune.

I would also especially thanks to Prof. Ashoka Todmal, Training & Placement
In-Charge, MIT College of Food Technology, Loni-Kalbhor, Pune for their kind
and dynamic support for completing this task successful.

Last but not the least I would like to thanks Prof.F.L.Pathan, Prof. R.R.Andhale,
Prof.(Dr.)A.N.Devkatte, Prof.P.D.Shere, Prof.M.S.Pawar, Prof.D.N.Choudhari,
Prof.K.A.Mane, Prof.R.S.Agrawal for their great support and advice related to
In-plant training which is always valuable for me.

I express gratitude towards all my Teachers, Friends, & Family for their ever
support, guidelines and affection throughout our curriculum.
 DECLARATION OF STUDENT

I undergone the In-plant training at “ASSOCIATED BLENDERS

PVT. LTD., PUNE” from 15th December 2017 to 31st March 2018

for fulfillment of the requirement for the degree of Bachelor of

Technology in Food Technology.

I declare that this report is embodies the result of a piece of

bonafide work carried out by me under the supervision of Industry

Coordinator and no part of the report has been submitted to any

other university for the degree and diploma or publication.

Place: MITCFT, Pune Mr. Sutar Ajinkya Anil

Date: FTL-68/2014
Prof. (Dr.) Vasant N. Pawar,
Principal,
MIT College of Food Technology,
Loni-Kalbhor, Pune

CERTIFICATE

This is to certify that the agro-base industry training progress report

compiled on the basis of successful execution of in-plant training for tenure of
three month from 15 December 2017 to 31 March 2018 at “ASSOCIATED
BLENDERS PVT. LTD, PUNE” by Mr. Sutar Ajinkya Anil is satisfactory. The
Standard Operation Procedure notified by MAHATMA PHULE KRISHI
VIDYAPEETH, RAHURI are followed in co-ordination with Industry Co-
coordinator and MIT-CFT In-plant Training In-charge respectively to justify
preparedness of student for skill and expertise development and also enhance
the student entrepreneurship. The report is submitted to faculty of MIT College
of Food Technology in partial fulfillment of requirement for the degree of
Bachelor of Technology in Food Technology.

Place: MITCFT, Pune Prof. (Dr.) Vasant N. Pawar

Date: Principal
Prof. Ashoka D. Todmal,
Assistant Professor,
In-plant Training In-Charge,
MIT College of Food Technology, Pune

CERTIFICATE

This is to certify that the agro-base industry training progress report

compiled on the basis of successful execution of in-plant training for tenure of
three month from 15 December 2017 to 31 March 2018 ASSOCIATED
BLENDERS PVT. LTD, PUNE” by Mr. Sutar Ajinkya Anil is satisfactory. The
Standard Operation Procedure notified by MAHATMA PHULE KRISHI
VIDYAPEETH, RAHURI are followed in co-ordination with Industry Co-
coordinator and MIT-CFT In-plant Training In-charge respectively to justify
preparedness of student for skill and expertise development and also enhance
the student entrepreneurship. The report is submitted to faculty of MIT College
of Food Technology in partial fulfillment of requirement for the degree of
Bachelor of Technology in Food Technology.

Place: MITCFT, Pune Prof. Ashok D. Todmal

Date: In-Plant Training Coordinator
 INDEX

Sr. No. Titles Page No.

01. Company Profile 1
02. Product Profile 3
03. Safety Assurance 9
04. Legal Definations 10
05. Plant Description 15
06. Produce of The Unit 17
07. Precautions To The Unit 19
08. Product Raw Materials 20
09. Extra- Neutral Alcohol 21
10. De-Mineralized Water 23
11. Water Demineralization 24
12. Blending Section 27
13. Washing Section 30
14. Bottoling Section 32
15. Aseptic Packaging 34
16. Storage & Dispatch 36
17. Effluent Treatment Plant 38
18. Quality Control 39
19. Dry Laboratory Operations 40
20. Methodology of Quality Rejection 45
21. Sensory Laboratory Operations 46
22. Wet Laboratory Operations 48
23. Outcomes 51
 PLEADGE OF CONFIDENTIALITY

I heartily respect each and every decisions of Associated Blenders Private

Limited that correlates with the Industrial Training, undertaken as a part of the
Internship Programme of three and half months. I also understand the fact that
there are different levels of confidentiality in a liquor industry. Therefore, I
hereby take pledge to strictly abide by the rules and regulations of the company
and always honour and maintain the confidentiality of the company, as a
developing professional. I assure to refrain from any activities that may
potentially harm the reputation and goodwill of the business corporate. In this
context, I would like to mention that being a representative of my institution
MIT College Of Food Technology,Loni-Kalbhor,Pune. I feel honoured and
hereby pledge to carry forward the reputation to the industry during my
internship programme.
 Chapter 1
COMPANY PROFILE
The liquor industry can be associated with either unbelievable success or heart-
breaking defeat. A sound recipe that captures the imagination, and delights the
palette is just not enough, rather it is more of a series of prerequisites that are
required to be planned and executed at corporate level for establishment of a
specific brand. There are licenses to obtain, production to arrange, and logistics to
be planned. But Associated Blenders Pvt Ltd overcame all these hurdles and
exhibited its presence in almost all alcohol categories to emerge as one of the
leading IMFL (Indian Manufactured Foreign Liquor) companies that manufactures
and sells alcoholic beverages all by itself.
The emergence of ABPL is believed to be around 2002, when Mr. Sadanand
Bapat,Anjali Bapat & Murali Ramchandra, the founder of Associated Blenders Pvt
Ltd(ABPL), makes the partnership with Vijay Mallya and moved on with a
Multiple brands ―McDowell‟s No.1,Royal Challege,Bagpiper,Signature under his
belt.
ABPL‟s flagship brand McDowell’s No.1 historically targeted the economically
marginalized sections of the society especially, the daily wage earners. It made
possible for every common man to have a taste of the best.
In the following years, ABPL introduced semi-premium versions of McDowell‟s
No. 1, McDowell‟s No.1 Reserve Whisky,McDowell‟s No. 1 Platinum Whisky,
Bagpiper Deluxe Whisky to extend its consumer scope. The black variety is a
blend prepared using Indian grain spirits and rare Scotch malts that have been aged
in charred oak barrels. Currently, McDowell‟s No. 1 is regarded as one of the
largest-selling whisky brand in the world, and is one of the largest spirits brands
exported out of India.

1
Since the last seven years, the pace of transition for DIAGEO (Formerly United
Spirits Ltd.) is such that today, United Spirits Ltd. is a multi-brand company with a
strong presence in 17 countries. The other major brands of USL are McDowell‟s
No.1 Reserve Whisky,Director Special Whisky, Bagpiper Deluxe Whisky, Royal
Challenge Whisky,McDowell‟s Celebrtion Rum, Premium Romanov Vodka has
emerged as the fastest growing spirits company in India with a compounded
growth rate of 23% over the last 3 years.

With 15 sales offices and 50 bottling units (of which 8 are company-owned), and a
pan-India presence, USL currently enjoys a national market share of approximately
11% in India„s alcoholic beverage industry in FY 2015-16.

2
 Chapter 2
PRODUCT PROFILE

Associated Blenders Pvt Ltd (ABPL) proudly presents itself as a multi-brand

company initiating from the whisky segments that includes products like

01. McDowells No.1 Reserve Whisky-

McDowell's No.1 Reserve Whisky was launched in 1968, and is a blend of

imported scotch and Indian malt whiskies. McDowell's No.1 whisky is sold in
several countries apart from India, including Africa, Canada, the Far East, Japan,
the Middle East and the United Arab Emirates.
 4th largest selling whisky in the world
 Market leader with 60% market share.
 India‟s favourite whisky due to constant innovations in
packaging,Marketing promotions & consumer events helped to
maintain ledership

02.McDowells No.1 Platinum Whisky-

McDowells No.1 Platinum Whisky launched in January 2013. It is a blend of
Imported scotch and selected Indian malt whiskies.
It is Famous because of unique blend and attractive packaging.

3
03.Bagpiper Deluxe Whisky-
Bagpiper is a brand of Indian whisky, manufactured by United Spirits Ltd (USL),
a subsidiary of the United Breweries Group, and launched in October 1976.
Bagpiper is sold in a square bottle with black and gold packaging design. The
company describes the whisky's flavour as "a light malty aroma and a hint of a
smooth woody character, owing to the use of malt spirits specifically matured in
pre-identified American oak casks" It is similar to a blended whisky flavored
with pot still malt whisky, but the neutral spirits used as base are distilled
from molasses instead of grain.
The brand uses tamper-proof bottles. It also introduced whisky in Tetra Pak.
Bagpiper was the seventh largest selling spirits brand by volume in 2010,
according to London-based liquor research firm International Wine & Spirit
Research (IWSR). The brand sold 16.92 million cases of 9 litres each that year.

4
04.Haywards Fine Whisky- The Haywards Fine whisky launched in 2013 by
United Spirits ltd. It is manufactured by using selected indian grain malts.
 Famous because of Fine and smooth.
 Attractive packaging is also a key behind the success of this brand.

05.Director Special Whisky- The Director Special Whisky is One of the

important brands of the United spirits. It is launched in India in 1985
 Famous because of the unique blend
 It is molasses based whisky.
 One of the leading market share in India and US.

5
06.Director Special Black Whisky- The Director Special Black Whisky is one of
the important product of United Spirits. It is launched in India in 1988.
 Famous because of its unique blend and attractive packaging.
 It is molasses based whisky.
 One of the leading market share in India and Us.

07.Royal Challenge Whisky- Royal Challenge whisky is one of the important

product of United Spirits Pvt Ltd. It is the grain based whisky blended in scotch
malts and Indian malts.

6
  Largest selling premium whisky brand in India.
 24 yrs of heritage
 Market leader with 33% share.
 One of the finest whisky and widely accepted over two decades in India.

08. Signature Whisky- It is one of the most important brand of of United Spirits
Pvt Ltd. It is launched in India in 1994. It is the blend of Imported Scotch whisky
and locally produced products. Signature is sold in Octagonal bottles which are
designed in London.
 One of the fastest growing brands in USL portfolio
 Exquisite whiskies from Scotland have been combined perfectly with finest
aged Indian malts.
 It is also famous because of world class blend, Attractive and unique
packaging .
 Sharpely Positioned on “Success is Good Fun” .

7
 09.McDowells’s Celebrtion Rum- It is one of the important product of
United Spirits Pvt Ltd.It is launched in 1990-1991. It is world famous brand
of Rum with „Bacardi‟ and „Old Monk‟
 3rd largest Selling brand I Of Rum in world.
 One of the global market leader
 Unique blend that is widely accepted globally.

10.Premium Romanov Vodka- It is one of the important brand of Vodka

manufactured by United Spirits Pvt Ltd.It has two star rating from
International Taste And Quality Institue.
 It launched in brand new world class contemporary packaging
 It is also famous because of its unique triple distilled blend.

8
 Chapter 3
SAFETY ASSURANCE

Every individual considers safety as his or her primary concern. The term Safety is
not merely about being physically fit rather, it associates now with many aspects
including quality. Therefore, Safety has been identified as a game changer with a
significant role to play in this era of globalization. In this context, it is worthwhile
to claim that safety is one major characteristic factor who establishes quality.
Recently, the world witnessed some of the safety systems like HACCP, ISO
22000:2005 to take care of the risks and safety hazards in manufacturing plants
very efficiently. Although, the system demands several pre-requisite programs
before it can function but once, all these PRPs are checked, the system takes no
time to eliminate for the best or reduce their limits to an accepted level.
Understanding the fact that the liquor industry is prone to frequent hazards which
when uncontrolled can lead to heavy damages in terms of money and goodwill of
the company, USL & ABPL has incorporated Safety Assurance system to each of
their processing phases. This strategy deserves applaud as it integrates quality into
the process. By sailing on their constant innovation, ABPL cruises to realize its
vision ―To be the most admired spirits company.

While taking plant safety into consideration, it is also a significant area of concern
for a liquor manufacturer like ABPL. Like every alcoholic beverage company,
ABPL too is in fond of glass bottles as a primary packaging, due to its inertness,
ease of recycling and a classy show attracting consumers at a glance. So, working
with it makes it susceptible to breakage bringing in various hazards to the system
as well as to the workers and employees. This calls for an effective safety
management strategy to be in place ensuring overall safety of the working
environment.

In addition to plant safety, fire accidents are frequent threats to any liquor industry
due to the fact that these industries deals with spirits and alcohol, considered as
good inflammables. Fire fighting proves to be another challenge needs combated
with. For an efficient safety management, proper induction, providing safety
accessories and frequent monitoring are inevitable.

9
 Chapter 4
LEGAL DEFINATIONS
Indian Standards
ALCOHOLIC DRINKS

Indian Made Foreign Liquor:

IMFL is primarily referred to spirits that are produced in foreign countries and
imported to India in bulk quantities and bottled in an Excise Bonded Warehouse by
the Importers such as Vodka, Whisky and Brandy.

Rectified Spirit:
Rectified spirit (revised) are considered to be inferior, thus they fail to qualify for
use in the manufacture of alcoholic drinks.
Neutral Spirit:
Neutral spirit is ethanol, which will only have the characteristic taste and odour of
ethanol.
Molasses Neutral Spirit: Neutral spirit made from molasses will be called
Molasses Neutral Spirit.
Grain Neutral Spirit: Neutral spirit made from grain or malt will be named as
Grain Neutral Spirit.

Whisky:
Whisky is a distilled alcoholic liquor possessing the distinctive colour, aroma and
taste of whisky. Whisky shall be made either from neutral spirit conforming to IS
6613 or rectified spirit, Grade I, conforming to IS 323 or a mixture of both.
 Malt or Grain Whisky: Malt or Grain Whisky shall be the alcoholic
distillate produced from fermented mash of malted or unmalted cereals or
mixture of both. The distillation shall be carried out to a suitable strength in
such a way that the distillate has a distinct aroma and taste characteristics
derived from raw materials or constituents formed during fermentation.
 Single Malt Whisky: It shall be the alcoholic distillate produced from
fermented mash of malted barley and distilled in pot still only.

10
  Blended Malt or Grain Whisky: Blended malt or grain whisky shall be a
mixture of at least 2 per cent malt or grain whisky with whisky.

Rum:
Rum is an alcoholic distillate obtained from fermented sugarcane/sugar beet
molasses, possessing distinctive aroma and taste characteristic of rum.
White Rum: Rum without colour shall be designated as white rum.
Premix Rum: Premix rum shall be alcoholic beverage made out of rum and
flavourings, with or without colour and with or without added sugar.

NATIONAL AGENCY FOR FOOD AND DRUG ADMINISTRATION

AND CONTROL ACT 1993 (NAFDAC)
(AS AMENDED)
Spirit Drinks Regulations 2005
Blended Spirit:
Blended spirit shall be a spirit obtained from alcohol of agricultural origin and
permitted additives with or without sugar(s).
Spirit drink: “Spirit drink” means an alcoholic beverage :
intended for human consumption;
having particular organoleptic properties;
peculiar to that class of drinks;
which contains a minimum alcoholic strength of 15% volume; and
shall be produced by one of the following methods -

fermented products, or
maceration of vegetable substances, or

agricultural products or a combination of two or more of the above to ethyl alcohol

of agricultural origin, or

11
 –

natural flavourings, permitted food colours, sugars or permitted sweetening agents.

Whisky: Whisky shall –

be a potable alcoholic distillate obtained from a mash of cereal grain products;
be saccharified by the diastase of the malt contained therewith or without other
natural enzymes;
be fermented by the action of yeast and matured for a period, contain not less than
37.0 per cent of absolute alcohol by volume.

Malt Whisky:
Malt whisky shall be the whisky obtained by distillation of a mash consisting of
cereal malt fermented by the action of yeast or a mixture of such distillate and
ethyl alcohol of agricultural origin.

Scotch Whisky:
Scotch whisky shall be whisky distilled and matured in Scotland qualifying in
accordance with the laws applicable thereto in Scotland.

Irish Whisky:
Irish whisky shall be whisky distilled in Northern Ireland or in the Republic of
Ireland as Irish whisky for domestic consumption in accordance with the laws
applicable thereto in Northern Ireland or in the Republic of Ireland.

Canadian Whisky:
Canadian whisky, Canadian rye whisky or rye whisky shall be whisky distilled in
Canada as Canadian whisky for domestic consumption in accordance with the laws
applicable thereto in Canada.

12
 Blended whisky:
Blended whisky shall be ethyl alcohol of agricultural origin to which permitted
whisky flavours have been added.

Rum: Rum shall –

Be a potable alcoholic distillate obtained exclusively from sugar-cane products;
Be fermented by the action of yeast or a mixture of yeast and other organisms; or
Be a mixture of such distillate which has been aged;
Have the aromatic characteristics specified to rum and may contain caramel, may
be flavoured with fruit or any other approved botanical substances/ flavourings;
and
contain not less than 37.0 per cent of absolute alcohol by volume.

Blended Rum:
Blended rum shall be ethyl alcohol of agricultural origin to which permitted rum
flavours have been added.

Vodka: Vodka shall –

be the potable alcoholic beverage obtained by the treatment of grain, potato spirit,
molasses spirit with activated charcoal, or the rectification of ethyl alcohol of
agricultural origin, so as to render the product without distinctive characteristic
aroma or taste; and
contain not less than 37.0 per cent of absolute alcohol by volume.

Caramel:
Caramel shall be prepared from the food grade carbohydrates or their combinations
in the presence of food grade acids, alkalis or salts.

FOOD SAFETY AND STANDARDS

(FOOD PRODUCTS STANDARDS AND FOOD ADDITIVES)
REGULATIONS, 2011
Type-I-Plain Caramel:
It shall be prepared by heating carbohydrates with or without acids or alkalis, or
their salts. No. ammonium or sulphite compounds are used.

13
 Type-II-Caustic Sulphite Caramel:
It shall be prepared by heating carbohydrates with or without acids or alkalis or
their salt in the presence of sulphite compounds; no ammonium compounds are
used.
Type - III - Ammonia Process Caramel:
It shall be prepared by heating carbohydrates with or without acids or alkalis or
their salts in the presence of ammonium compounds; no sulphites are used.
Type-IV- Ammonia Sulphite Caramel:
It shall be prepared by heating carbohydrates with or without acids or alkalis or
their salts in the presence of both sulphite and ammonium compounds.

14
 Chapter 5
PLANT DESCRIPTION

Assocciated Blenders Private Limited (A unit of DIAGEO India formerly United

Spirits Ltd) is Located at The plant is proud of its state-of-the-art infrastructure
having a production capacity of 1 lac cases per month and is strictly allowed to sell
its produce under the Maharashtra State Excise only. ABPL plans to upscale it to
1.5 in the years to come.
The unit operates in General Shifts with a schedule time from 9:00am to 5:00pm
along with a lunch break of an hour in between. The initial and final hours of a day
are usually the rush hours as they decide the fate of production. It is endowed with
a good supply of water, used in its production operations only after
demineralization through two of its units.
The unit is bifurcated into various sections to facilitate sorted work area,
significant to withstand and overcome the pressure of production with ease. These
sections, functioning unanimously and arranging smooth operations related to
IMFL manufacturing can be identified as namely:

Water Demineralization Section (DM Plant):

It is responsible for the removal of mineral salts from water.

Washing or Rinsing Section:

Here, rinsing of the bottles with DM water is done to stabilize pH.

Blending Section:
Here, unit operations like filtration, reduction, mixing, etc. occurs.

Bottling Section:
It accounts for filling, labelling and packaging of the products.

Regional Quality Control Laboratory (RQCL):

It carries out inspection, tests and analysis to assure quality.

Effluent Treatment Plant (ETP):

It monitors, regulates and prevents environmental contamination and pollution.

15
16
 Chapter 6

PRODUCE OF THE UNIT

The plant focuses on some of the renowned and prestigious brands of the company,
which are in great demands in the states of Maharashtra. The products that form
the priority in the local and domestic markets in and around the manufacturing unit
are as follows:

01. McDowell’s No.1 Reserve Whisky

 2000 ml
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml
02. McDowell’s No.1 Platinum Whisky
 2000 ml
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml
03.Bagpiper Deluxe Whisky
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml
04.Haywards Fine Whisky
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml

05.Director Special Whisky

17
  1000 ml
 750 ml
 375 ml
 180 ml
 90 ml
06.Director Special Black Whisky
 750 ml
 375 ml
 180 ml
07.Royal Challenge Whisky
 2000 ml
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml
08.McDowell’s Celebration Rum
 750 ml
 375 ml
 180 ml

09.Signature Whisky
 750 ml
 375 ml
 180 ml
10.Premium Romanov Vodka
 1000 ml
 750 ml
 375 ml
 180 ml
 90 ml

18
 Chapter 7
PRECAUTIONS TO THE UNIT
Since an industry is involved in manufacturing of a product intended to satisfy its
customers in terms of quality to stay in a healthy status as a business entity. It
follows certain policies and implements them strictly at its units to safeguard its
goodwill in the market.
As an IMFL manufacturing unit, the responsibility to maintain safety and quality
towards all its stake-holders becomes very crucial. Some of the significant
precautions taken by the unit for are as follows:
The entry of inflammable substances (like matchsticks, kerosene, etc.) is strictly
prohibited in the unit.
The entry and exit of individuals are strictly restricted without appropriate
verification of their belongings.
Entry to the unit (especially to the shop floor) is strictly subjected to the approval
of the Department of Maharashtra State Excise.
The entry of the electronic goods to the unit is strictly prohibited.
Clean and perfect hygienic conditions are to be maintained in the production area.
Safety precautions are to be taken prior to entering the Washing and Bottling Hall.
Good Manufacturing Practises (GMP) needs to be exercised and its
implementation to be verified during production.
No kinds of fragrances are allowed within the unit, as the blend may get affected
with it.
Prior to dealing with the manufactured product, one should take proper precautions
to avoid contamination.
Use of cell phones in the Bottling Hall is strictly limited and need to be checked by
the concern authorities.
While working with chemicals, care should be taken so that no contamination may
take place.
Storage Area is to be restricted and monitored with close-circuit cameras.
The demineralized outlet is to be monitored frequently.
The composition of the key ingredients of the products should not be disclosed to
outside to safeguard its business policies.

19
 Chapter 8
PRODUCT RAW MATERIALS
Most of the IMFL manufacturers depend heavily on foreign imports especially, on
the European countries such as Scotland, Ireland, Netherlands, Spain, etc. for the
concentrates constituting the X-factor of the alcoholic beverages. ABPL is not an
exception to it.
Besides these flavouring spirits, they possess the support of the indigenous grain
spirits that arrives from various parts of the country, depending on the suitability of
supply and demands and seasonal variations. The Demineralized water is a basic
requirement of a plant as it cleanses the containers and bottles before filling the
blend. It is also seen to be in action while, it reduce the alcoholic strength of the
ENA charged to the tank. Therefore, a liquor bottling plant needs to be self-
sufficient in terms of the Demineralized water supply. The lovely colour of the
blend is possible due to the deliberate addition and mixing of the food additive in
caramel. A brown to dark brown colour inculcates the ethnic beauty of flavoured
spirits and alcohol.
Extra Neutral Alcohol (ENA), a known ingredient in the IMFLs like Whisky,
Vodka, Gin, Rum, etc. is of special significance. The reason being the greatest
contributor and purest form of alcohol by volume. Thus, it forms the basis of
blending.
The identified key ingredients as the starting raw materials of the products are as
follows:
Extra Neutral Alcohol (ENA)

Demineralized Water (DM water)

Type I, Plain, Caustic Caramel

Scotch and Irish Malts

Flavours (CONFIDENTIAL)

20
 Chapter 9
EXTRA NEUTRAL ALCOHOL

Extra Neutral Alcohol or commonly, ENA is a double rectified alcoholic distillate

having 68.4ºoverproof with 96% of alcohol by volume. It shall conform to the
following requirements to be used for alcoholic drinks, as specified in IS
6613:2002:

Characteristic Vodka Others

Relative Density at 20˚C 0.80692 0.80692
Ethanol percent v/v at 40˚C 96 96
Miscibility with water Miscible Miscible
Acidity as acetic acid, gm/100 1.5 1.5
lit. absolute alcohol, MAX.
Methyl Alcohol, gm/100 lit. 50 50
absolute alcohol, MAX.
Permanganate Reaction Time 30 30
in minutes,absolute alcohol
MIN.
Higher alcohol as isopropyl 30 30
alcohol gm/100 lit,absolute
alcohol MAX

ENA, derived mostly from the selected variety of high quality is procured from the
nearby distilleries such as distilleries of Viraj Alcohols And Distilleries, Shirala
Dist. Sangali.The procurement entirely depends on the significant factors like cost,
quality, distance from the unit, etc.
ENA, free from impurities (checked using GC chromatography) reaches the unit
through long-distance tankers having five compartments. The sampling of ENA
from each of the five compartments is followed before acceptance by the unit,
which are analysed in various phases. The sequential phases involved from
procurement to acceptance are as follows:

GC chromatography: done in manufacturing distilleries using GC/MS.

Sensory analysis: done in the receiving unit as Bouquet and Pallet tests by trained
panellists.

Strength determination: done in the unit for payment to suppliers.

21
PRT test: done to check the purity of ENA, indicating using the delay in colour
appearance.

The quality passed bulk ENA is transferred to the ENA tanks at the receiving point
of the unit and the tankers are flagged off for return.

22
 Chapter 10
DEMINERALIZED WATER
Demineralization or deionisation is the process of removing mineral salts from
water by using the ion exchange process.

Raw Water Analysis Report

Characteristic Value
Turbidity 0.2 NTU
TSS 23 ppm
pH at 25˚C 7.5
Conductivity 1142.85 µmhos/cm
Total Dissolved Solids 800 ppm
Total Hardness 400 ppm
Iron (As Fe) 1.5 ppm

As the report suggests that the source water contains high degree of cationic and
anionic impurities, rendering it unsuitable for alcohol reductions as it may possibly
catalyse the oxidation-reduction reactions to give rise to fractions of aldehydes,
ketones and other higher alcohols like amyl alcohol (by the virtue of its mineral
content) besides imparting hardness to water. Moreover, it may lead to high
mineral acidity. This calls for the effective demineralization operation in a liquor
manufacturing unit.
Demineralization involves two ion exchange reactions. Initially, the cations such as
calcium magnesium & sodium are removed by hydrogen ion (H+). The salts thus
converted into their respective acids by this exchange. The acidic water is then
passed through an anion exchange where the anions such as sulphates chlorides
etc. are removed by HYROXYL (OH-) ions.
The basic Scheme of reactions that takes place during a demineralization reaction
is:

RH + Na+ ------- R-Na + H+ (For cation)

R-OH + Cl- ------- R-Cl + OH- (For anion)
H+ + OH- -------- H2O

23
 Chapter 11
WATER DEMINERALISATION SECTION
The unit has state-of-the-art water demineralization section to impart soft water of
higher purity where it regulates or rather minimises the mineral content to an
acceptable limit. The significant processes that make the water demineralization
realized:

Oxidation Chamber:
The purpose of the chamber is to oxidize the reactive metals in traces and minerals
in the incoming water source using manganese dioxide (MnO2) present in the bed
in the form of manganese boulders
.
Iron Removal Filter:
The Filter accounts for removal of the ferrous salts dissolved in water using a
proper media. It removes suspended Iron through a sequential series of steps
namely, Rinse, Service, Backwash Rinse and Fast Rinse.

Dual Media Filter:

The filter with a special anthracite media above the conventional sand media has
special surface properties due to which the small colloidal particles get attached to
its surface removing particulates greater than 30μ. Due to this property, the DMF
filter is widely used in pre-treatment of RO systems releasing water with turbidity
less than 5 NTU.

Activated Carbon Filter:

The Activated Carbon Filter is employed for removal of residual chlorine, removal
of organics and removal of odours. The removal of contaminants by employing
activated carbon is both by a physical and chemical adsorption. Removal of
chlorine by activated carbon is basically a chemical phenomenon.
C + HOCl = CO+ H+ + Cl-

Reverse Osmosis System:

The system utilizes high pressure-driven high rejection–high flow membrane
process that is capable of separating dissolved solutes from a solvent (water)
through a semi-permeable membrane. It requires the dosing of ‘Antiscalant’ to
inhibit scale formation by concentrated salt on the membrane. Water supply To
DAY Tank.

24
Mixed Bed Filter:
The filter-cum-polisher consisting of specially designed vessels in which SAC and
SBA resins are embedded functions to remove the residual traces of silica and
sodium ions (in ppb).

Strong Acid Cation (SAC):

It caters to remove hardness only when SAC resin in Na+ form whereas, in H+
form, the cations including sodium ions are exchanged for H+ ions leading to the
release of free Co2 by decationization of alkaline salts in the raw water
.
Strong Base Anion (SBA):
These are the resins, usually of two types developing their functionality from
quaternary ammonium salts. Type I, being more stable is more suitable for total
anion removal and dissolved Co2 in water.

Degasser Tower:
The Degassifier unit facilitates the escape of the dissolved volatile gaseous
pollutants like free Co2 dissolved in water by the application of blower and then
passing it through a series of filters before emission to the surrounding .

25
 Raw Oxidation Sand Dual Activated

water Chamber Filter Media Carbon

Filter

Sand
Cationic RO
Filter
Bed water
Filter Storage RO
Degasser HPP

Anionic Mixed DM

Bed Bed Storage

Filter To DAY Tank

26
 Chapter 12
BLENDING SECTION
Even today, blending remains more of an art than a science, as leading players of
the game are unwilling to reveal the secrets of blend formulation. Blending,
pioneered by Andrew Usher, in Edinburgh, in the early 1860s provides the distiller
with an opportunity to create a product with unique and recognizable flavour
attributes to attain product consistency and establish a brand. Thus, Blending is
reclaimed as the heart of the IMFL, owing to the influences of a wide range of
processing and maturation parameters. This operation focuses mainly on four on
areas:

These four areas are supervised by a Master Blender, leading the blending team. A
blender, with his loads and loads of experience utilizes his most-sensitive
instrument „the nose‟ to judge the overall flavour profile of the blend.
Associated Blenders Pvt.Ltd. believes in quality Blending and so, the unit holds a
well established blending section with a good team of self-efficient blenders. The
blending hall comprises of:

The estimation of the blend preparation is done by using the „Blend Formulae’
which is as follows:

Volume of Blend = (Volume of ENA (in BL)*ºProof (ENA))/Required ºProof

The Formula reveals that, it is the volume of ENA that dictates the volume of
blend. Thereby, the ENA is important in blending operation.

27
 28

PROCESS FLOW OF BLENDI NG

Conc. Bypass

Carame

Knife
Blendin Day
Mixer g Tank
Filling
Circulatio Point
n
Spirit
Circulation

ENA Tank
Strong

Spirit
Tank

28
 28

PROCESS FLOW OF BLENDI NG

Conc. Bypass

Carame

Knife
Blendin Day
Mixer g Tank
Filling
Circulatio Point
n
Spirit
Circulation

ENA Tank
Strong

Spirit
Tank

29
 Chapter 13
WASHING SECTION
Washing refers to the process or technique to clean any surface usually with stream
of water. In this particular context, it can be technically termed as the Rinsing
operation taking place because the stream of fluid is directed towards both the
inner and outer surfaces of the targeted material with a purpose to homogenize the
material with a specific fluid.
The liquor industry depends generally on glass bottles because of its decorative
and royal appeal to the customers. The market return glass bottles are also utilized
(if unbroken) again for bottling of new blend. This practice not only saves money
of the company but also reduces the load of environmental pollution and saves
energy too. But on the other hand, those market return bottles obviously would
contain dirt, mud, and various foreign particles, forcing rinsing operation
mandatory.
The unit, being well equipped with the processing of DM water finds enough use
of it in this section. The process is designed in such a way that the demineralized
water is supplied continuously to the machines indirectly from the Day Tank,
through 10μ cartridge filters, maintaining a pressure all through. There are two
kinds of rinsers installed in the plant namely:

Automatic rotary rinsers: The machine named ‗GRIPMATIC„ having 50 (for

Lines 1 & 2) or 40 rotating heads (for Line 3) with an optimum operational speed
ranging from 300 (for Lines 1 & 2) to 180 BPM (for Line 3) efficiently rinses
bottles with jet spray of demineralized water, one from below through the neck
opening and the other from the top to ensure complete homogenization with DM
and remove any particles adhering to the body surface with pressurized jet flow.
Semi-automatic rotary rinsers: This machine (for Lines 4 & 5) operates in the
same way as the automatic one except the differences in design, making it a low
operating machine.

Although, the designs of the machines are completely different to each other, both
work on the same technology. The demineralized water is pumped through a
booster pump to the machines from Day Tanks via an intermediate reservoir
having a float valve maintaining a constant.

30
water level. The machine receives water supply from two separate reservoirs for
two jet flows.
The technology that the machines follow is to divide one of the channel flows
radially (under centrifugal force) to help obtain the jet at required positions
(usually two). The other channel is left as it is and used to rinse the outer surface of
the bottles by a jet flow from the top through minute pores or openings. In this
way, the bottles come three times in contact with demineralized jet spray in a cycle
of rotation.
In Line 1, the rinsing operation is incorporated along with the filling and cap
sealing operations in a single machine thus, helping to minimise the man power
requirement, loss of money and time and increasing productivity.

31
 Chapter 14
BOTTLING SECTION
Bottling deals mainly with the packaging of the blend of the liquor prepared in an
isolated section with a purpose to prepare as a saleable product. Due to the ever
increasing quality awareness amongst the customers, most of the companies have
pulled their shocks up to meet the stringent specifications as prescribed by the
regulatory bodies. Thus, this section helps to connect with its consumers in a true
sense.
Associated Blenders Pvt Ltd (ABPL) nurtures its bottling hall to not only retain its
existing customers but also to attract the new ones. The hall at the Hadapsar unit is
equipped with five (5) lines to cater the exponential demands of the customers. Out
of which, three (3) lines are automatic while the other two are semi-automatic, and
these are operated according to the requirements and suitability. The hall also
posses a state-of-the-art „Aseptic compartment‟ with two aseptic packaging
machines aligned serially that aseptically fill 90ml and 180ml No.1 whisky.
The rinsed bottles queue themselves and head towards the bottling hall after
making appearance from the rinser machines (except for line 1). On the other hand,
the blend is released from the Day Tanks through fabric cloth filters (CCP1) to
reach the filling machine. Most of the lines are almost similar in terms of their
operation, having the following processes incorporated into the systems:

Empty Bottle Inspection:

The bottles (both PET and glass) are inspected to promote quality control and this
point acts as Control Point (CP).

Filling:
A little ahead on the line, the bottles encounter filling machines, responsible for
bottling the in-line blend. The unit posses two kinds of fillers, depending on its:
Mode of action: gravity filling (for lines 1, 2 and 4) and vacuum filling (for lines
3 and 5).

Gravity fillers work by the free flowing ability of the blend under gravity. On the
other hand, Vacuum fillers work by creating voids through negative air pressure
application.

32
Cap feeding and Capp sealing:
Cap feeding may be done either manually automatically depending on the type of
machine employed. Capping a bottle though seems to be an easy job for these
machines. But, the varieties of caps make it complicated. Basically, they are of two
types namely Roll-On-Pilfer-Proof (ROPP) and plastic closures, which dictates the
type of capping machine used. The former gets sealed completely when both the
skurt and thread rollers are in action. But, the sealing of the latter is achieved by
tapping down the closure through the neck making a constant 5º angle with the
closure.

On-line Inspection:
This phase also acts as a CP, where the quality control is achieved through visual
inspection of the bottles along with the blend moving in a line and examined for
minute (quickly noticeable at arms length when inverted) particles suspended in
the blend mainly along with leakage due to improper sealing. The defective items
are isolated for rework.

Hologram and Label placing:

While, the hologram signifies the government„s approval of the product, the label
acts as a silent salesman for the company. Both these operations are performed
using the same technology, helped by a series of rollers. Line 3 is somewhat
different and dictated by the type of the label i.e. gum label (gum added
externally).

Mandatory printing:
Print Mandatory consists of Batch number, line number, costs (MRP) and the date
of manufacturing and achieved using Domino. The printing of the mandatory takes
place at three stages i.e. on the labels, monocases and bulk cases sequentially.

Final End of-line Inspection (EOL):

This phase also acts as a CP where the defects related to labels and hologram,
bottles, closures and on-line blend quality status are examined.

Packaging and Palletizing:

The palletizing refers to the placing of the cases (packaged) to mobile vehicles in
bulk to transport them to the bond space (storage area).

33
 Chapter 15
ASEPTIC PACKAGING
Aseptic packaging can be defined as the filling of a commercially sterile product
into a sterile container under aseptic conditions and hermetically sealing the
containers so that reinfection is prevented, making the product shelf-stable at
ambient conditions.
The unit is capable to produce aseptic whisky packs of 90ml and 180ml sizes
through its two premier machines Tetra Brik Aseptic.

Principle:

Operating pre-requisites:
-7.5 kg/cm2

Procedure:
The six-layered film reaches the strip applicator through a series of rollers where
the plastic strip gets attached to the film into molten state that passes through an air
knife for attaining stability. Gradually, the shape of the package is formed mainly
with the help of crease roller along its flow. When the film is longitudinally sealed,
the blend is released along with liquid nitrogen (in 9:1 ratio) and then transversal
sealing occurs using conductive heating and each package is isolated by the knife
attached.

Problems related to its operation:

LONG SHORT STOP

SHORT STOP

34
 Day

Tank Fabric Filter Rework

Blend Closures
Bottle Inspection

Filling Capping Cap Sealing

Bottles

On-line
Printing
Labelling Hologram
Inspection
Mandatory

Second Carton Partition Supply

Batch
Packaging
Inspection Forming Printing

Plates Supply
Carton Supply

EOL
Palletizing
Inspecti
on

35
 Chapter 16
STORAGE AND DISPATCH
The unit has specific storage facilities for packaging materials as well as for
the finished goods (FG) and are identified using stock keeping units (SKUs)
recorded during their arrival at store.
The quality-passed palletized finished goods arrive at the bond store where
they are stacked on the basis of Batch number and variety of the product.
The height of each stack depends on the quantity and the variety of the
product. The content of whisky bottles incase varies according to the
volume of bottles, is tabulated as follows:

Volume of bottles (ml) Size of bo ttles

1000 ml ( LITRE) 12
750 ml(QUART) 20
500 ml 24
375 ml( PINT) 42
180 ml(NIP) 48
90 ml 48

The storage area has maximum holding capacity of around 80,000 cases. But, the
actual storage is limited to 55,000 due to certain obligations.
The despatch of the stocks involves several steps:
Stock Check

ontrolled)

Transfer of Bond to Trade: requires duty clearance by the distributor, preparation

of requisition by the licensee and conversion of FG from bond trade to Company
trade.

Transfer of FG from company Trade to distributor Trade: requires issue of various

documents to the distributor.

Preparation of documents like invoices and passes.

36
Only after transfer of goods to distributor trade, the distributor has permission to
access the product from the storage area. The finished goods are transported from
the unit to the distributor through long-distance transport.

37
 Chapter 17
EFFLUENT TREATMENT SECTION
The processing unit utilizes huge quantities of water resources in a regular basis
during its manufacturing operations like rinsing, blending, etc. However, the
former operation also involves the discharge or drainage of the resource to a high
level. However, the quality of the water deteriorates during drainage due to various
levels of contaminations during operation, which when let untreated can lead to a
havoc damage to the surrounding environment. This signifies the set-up of an
effective Effluent Treatment Plant (ETP).
The main identified industrial effluents observed in the processing waste water of
the unit are as under:

Packaging materials: include broken glass bottles, cc box parts, etc.

Dissolved chemicals: include acids, bases and salts.
Dissolved organics: include odoriferous and quaternary compounds.
Suspended particles: include fibre particles discharged with blend.
Dissolved gasses: include free Co2 emission.

The treatment of the discharged effluents can be by the help of the following
process flow diagram:

PROCESS FLOW OF EFFLUENT TREATMENT

AC
F

Aeratio Aeratio
n Compresso n
r
Lim Aeratio
e n Polychlori Aluminiu
de m

Tank Hypochlori
1 de
Tank
2
Drain Tank
3
wate

38
 Chapter 18
QUALITY CONTROL
The plant has a federal support of Regional Quality Control Lab (RQCL) stationed
at the unit. It has wide range of responsibilities starting from the sampling of
incoming raw materials and packaging materials to the quality control of the final
products. Its operational functions are even more diversified by cross-unit checks
and sensory analysis of other tie-up units. In this context, it is significant that
RQCL has provision to validate with reference to its internal standards and award
silver certificate within its internal system of network and is also ranked 2nd (only
after CQCL) as far as internal certificate issuing authority.
The quality control team works for RQCL to detect quality related issues in the
plant and has the following duties to carry out without compromising with the
quality.
Inspections of the packaging materials are carried out at RQCL, categorizing
defects and following a simple strategy for acceptance accordingly.

Materials Sampling volume Acceptance Limit

Glass bottles 4% (SKU) <0.05% (critical defects)
PET bottles 4% (SKU) <0.05% (critical defects)
ROPP closures 4% (SKU) 0.00% (critical defects)
Labels 4% (SKU) 0.00% (critical defects)
Monocartons 4% (SKU) 0.00% (critical defects)
CC Boxes 4% (SKU) 0.00% (critical defects)

Similarly, raw material are sampled and inspected with sensory analysis mainly.
The analysis of the raw materials like demineralized water and caramel involve
chemical analysis.
RQCL is partitioned into three respected sections to facilitate free, competitive and
professional work environment. The sections are:
Dry Laboratory: deals with analysis the packaging materials.
Sensory Laboratory: an isolated room for judging sensory attributes.
Wet Laboratory: deals mainly with blend and other raw material analysis.

39
 Chapter 19
DRY LABORATORY OPERATIONS
The dry laboratory is concerned with sampling and analysis of packaging materials
like bottles (glass and PET), closures, monocases, cc boxes, etc. The quality team
categorizes defects of a packaging material into three limits namely:
Critical defects: The defects that cannot be tolerated since it may cause a potential
threat to the customers on use and in turn affect the reputation of the company and
its brands.
Examples - broken bridge, missing mandatory, glass imperfections, etc.

Major defects: Those defects that can be tolerated to a minimum permissible limit
that maintains stringent quality standards.
Examples – damaged cap, fill height variation, fibre particle, etc.

Minor defects: Those defects that do not harm its consumers at all, but their
control is necessary to protect the goodwill of the company.
Examples – cut graphics, brush marks, shade variations of labels, etc.

The work process of the laboratory is described serially on the basis of packaging
materials:
Bottles (glass and PET):
Visual Inspection: refers to the detection of physical appearance change and
categorizing according to the types of defects (critical/major/minor).

Dimensional Analysis: refers to the conformation of the dimensions with the

internal specifications and standards as follows-

Parameters (1000m l) Instrument used Range (for glass)

Weig ht (gm.) Weighing machine 589 -591
Brim Full Capacity (ml.) Graduate d Flask 1022 -1024
Vacuity (ml.) Vernier Callipers 44- 46
Major Axis ( mm) Vernier Callipers 92.60- 93. 05
Minor Axis ( mm) Vernier Callipers 89.12- 89. 77
Total Height ( mm) Erected Vernier 306 -308

GO NO-GO Test: quick test for conformance for exact dimensions of the closures
to neck of the bottle. There are two opposite faces that tests for GO (should
conform) and NO-GO (should not conform).

40
 Apparatus/Models (for NIP) Function
Cap ID Checks cap fitting
Thre ad OD Checks uniformity in threads
Bottom OD Checks cap locking
Anchorage OD Checks for uniform anchors
Lugs OD Checks for smooth rotation

Closures ((ROPP-28 & 30mm and plastic):

Visual Inspection: refers to the detection of physical appearance change and
categorizing according to the types of defects (critical/major/minor).
Examples – improper liner, knurl defects, broken bridges, etc.
Dimensional Analysis: refers to the conformation of the dimensions with the
internal specifications and standards as follows-

Parameters (30mm ) Instrument used Range (for ROPP)

Outer diameter ( mm) Vernier Callipers 29.48- 29.59
Inner diameter (mm) Vernier Callipers 28.67- 28.75
Ring Height ( mm) Vernier Callipers 5.96 -604
Width Bridge ( mm) Graticule Magnifier 0.9 -1.0
EPE Liner ( mm) Screw Gauge 1.399- 1.420
Metal Thickness (mm) Screw Gauge 0.205- 0.209

Closures Pull-Out Test (plastic):

SOP-

closure at least for 20 seconds.

If the Closure do not pulls out, the test turns negative, indicating that the closure
is good enough to be sealed.

Light Test: tests the uniformity of the perforation height by passing light through it
in dark condition.

41
Labels and Monocartons:
Visual Inspection: refers to the detection of physical appearance change and
categorizing according to the types of defects (critical/major/minor).

Examples – excessive ink, colour variations, incorrect texts, etc.

Dimensional Analysis: deals with measuring the dimensions (length*width) and
conform the same to the internal specifications or standards.

Scuff Resistance:
Purpose: test the degree of resistance to aberration.
Instrument: Scuff Resistance Tester
SOP:
ttached to the instrument (bigger and
smaller).

At the end of rotations, if the labels are found to be in undisrupted state, then the
test is negative.
Alcohol Resistance Test (also applicable for monocases):
Purpose: test the reaction or effect of the blend on the label.
Chemicals: Alcohol (42.8% ABV)
SOP:

At the end of rubbings, if the labels are found to be in undistorted state, then the
test is negative.
Grain Direction Test (for labels):
Purpose: test for any possibilities for forming arrow heads.
Material: Flowing water

42
 SOP:
l in flowing water in such a manner that it„s back side gets wet.
-15 seconds.

After a certain time, if the labels are found to be somewhat folded toward the front
side, then the test is negative.

Corrugated Flute Cartons and its allied material:

CC boxes play an important role, providing good strength and support against
external forces. The tests associated with it are:
Visual Inspection: refers to the detection of physical appearance change and
categorizing according to the types of defects (critical/major/minor).

Examples – excessive ink, misplaced texts, incorrect texts, etc.

Dimensional Analysis: deals with measuring the dimensions (length*width*height)
and conform the same to the internal specifications or standards.

Moisture Analysis: deals with measuring the % of water absorbed and compare the
same to the internal specifications or standards.

Bursting Strength:
Purpose: tests the maximum pressure withstanding capacity.
SOP:

the instrument.
‗START„ button until the box tend to burst.

After releasing the ‘START’ button a continuous beep prevails, and the instrument
shows the BS value on the display. Grammage Tester Scuff Tester Bursting
Strength Tester Tester

43
Grammage Test:
Purpose: tests the gsm of the material
Instruments: Hot Air Oven and gsm tester.
SOP:

apart on its own overcoming their adhesiveness.

ly in gsm tester.

The mean of the calculated gsm is regarded as the gsm of the material.
DRY LAB EQUIPMENTS

Grammage Tester Scuff Tester Bursting Strength Tester

44
 Chapter 20
METHODOLOGY OF REJECTION
The packaging materials when rejected due to non-conformance of the quality
specifications undergo a rejection process which is outlined as:
Isolation of the rejected packaging materials.

Communication about the lot and quantity of rejections to the suppliers.

Crushing all the packaging materials that were isolated due to quality failure.

In case of closures:

suppliers.
ed.

In case of Bottles:

In case of corrugated cartons

The cartons are torned into pieces before they are returned.
The objective or rather motive behind this process of rejection is that the supplier
may not be able to serve the same material having quality defects after being
rejected due to destruction of its shape.

45
 Chapter 21
SENSORY LABORATORY OPERATIONS
The evaluation of the flavour of Indian Made Foreign Liquors (IMFL) by chemical
and instrumental methods or routine quality control is not practicable. The other
limitation of instrumental analysis is that it cannot integrate the flavour impression
as is gathered by human senses. The analysis of quality of IMFL can, therefore, be
done conveniently by sensory evaluation which gives the sum total of interaction
of different flavour components. This evaluation gets more effective with the
experience and routinely arranged trainings. The laboratory follows a strict routine
and has several restrictions in order to avoid any type of contaminations. The
following considerations are relevant in this regard.

Ideal Laboratory set-up:

as free from odours and sound as possible. This
can be achieved by air conditioning with activated carbon filters installed in the
system.

illumination. Special light effects, using coloured filters or bulbs may be desired to
hide irrelevant differences in colour and other aspects of appearance.

members.

out the tests.

Time of Analysis:

The test should be carried out by the Panelists between 10.30 to 12.30 h. The test
should not be carried out when the panelists are really thirsty.
Rules for sample preparation:
r a sample.

46
demineralized water (in 1:1 ratio).

Rules for sensory analysis:

each sample.
-to-right.
-
odours) as it makes our senses fresh and active.

and swirl it to homogenize the flavour and odour.

recording the
scores against samples.

47
 Chapter 22
WET LABORATORY OPERATIONS
Wet laboratory or the Chemical Analysis Lab mainly deals with the analysis of the
raw materials which are:
Raw water:
Hardness Test: employing Complexametric method (EDTA)
Principle: EDTA forms a chelated soluble complex when added to a solution of
certain metal ions.
Reagents: -
Ammonia buffer of pH 10.
0.02(N) solution of disodium salt of ethylenediamine tetra acetic acid.
Erichrome black T indicator solution.
SOP:

anges from red to

blue.
Calculations: Total hardness (as CaCO3) =(Titre value)*20=__ppm
Free Chlorine Test: (Free chlorine should be less than 0.2 ppm)
Reagents: -
Test CHLOR.
SOP:

the reagent in a measuring cylinder.

Demineralized water:
Sulphate Test:
Reagents: -
10% BaCl2 solution.

48
Chloride Test:
Reagents: - 1% AgNO3 solution
SOP:

well.
h-white haze
develops).

Alkalinity Test:
Reagents: - indicator solution
SOP:

change and compare against the standard.

ENA and Blend :

Mater ial/Tests Colo ur pH Turbidity Alcohol %
(Abs) (NTU ) (ABV )
ENA --- 5.7 -5. 9 ---- 96.5
No.1 Reserve 0.858- 0.867 4.58 -4.62 0.58 -0.82 42.8
No. 1 Platinum 0.780- 0.785 4.52 -4.62 0.49 -0.58 42.8
Royal Challenge 0.778- 0.780 4.52 -4.62 0.49 -0.58 42.8
*Subje ct to verification with the inter nal st andards

49
Type- I P lain, Caustic Cara mel :
S.N. Tests Characteristics
1. Colour Bright go lde n y ello w wit h re ddish tinge
2. Appe arance Thick ho mogeneous mixt ure
3. Odour Characterist ic sme ll of burnt sugar
4. Taste Ple asant bitter odo ur
5. Sp. Gravity (10%so l) 1.023
6. pH (1% solutio n) 3.4 -3. 7

Asept ic Package quality Test s :

S.N. Tests Procedure
1. Crease line
2. Vertical alig nment Visual I nspe ct ion
3. Horizo nal alignment
4. Taste Pleasant bitter odour
5. LS Overlap Measuring Inspe ction
6. Volume ( weight ) Weig ht Measureme nt
7. Flap Sealing Visual Inspection
8. Rough Check Handling Test
9. Accurat e Check Punch Instrume nt
10. Conduct ivity Test C-Meter
11. Longit udinal Seal Te st Visual Strip Inspe ction
12. Nitrogen Disso lve Sensory
13. Visual Check Batch Printing
14. Leakage Test Dye I nje ction

LAYERS OF ASEPTIC PACKAGING

50
 Chapter 23
OUTCOMES
Associated Blenders Private Limited, one of the giants in the field of IMFL
manufacturing in Maharashtra state is appreciated for its vision of continuous
improvement and quest for excellence along its journey towards becoming the
most admired spirits company of the world. Their true strengths have been their
innovative approaches towards product as well as the system, led by a tremendous
team that challenges inflation, maintains product quality and establish new brands.
The report tries to analyse the operation of the plant that caters delivery of good
quality IMFL brands with quality intact from the process line to the hands of the
consumers in a professional approach. It also tries to relate manufacturing
technologies giving emphasis to quality assurance with effective management in
response to certain special situations. The report may be seen as a survey of the
overall operations starting from procuring, testing, manufacturing and quality
control and assurance.
The experience at Associated Blenders Pvt Ltd. is very precious and enriching. The
training has inculcated knowledge regarding alcoholic beverages, the necessary
skills associated with IMFL manufacturing and above all, to be a competitive and
target-oriented professional, working in a team.

51