Seerat Internship Report

"And it is He who sends down rain from the sky, and We produce thereby
the growth of all things. We produce from it greenery from which We

produce grains arranged in layers. And from the palm trees - of its
emerging fruit are clusters hanging low. And [We produce] gardens of
grapevines and olives and pomegranates, similar yet varied. Look at [each
of] its fruit when it yields and [at] its ripening. Indeed in that are signs for a
people who believe." (Qur'an, 6:99)
2020
INTERNSHIP REPORT
Seerat Saleem
SHEZAN INTERNATIONAL
LIMITED, LAHORE
3/20/2020
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Seerat Saleem
2016-ag-8260
8th semester
A report submitted in the fulfillment of

the requirements for the degree of
B.Sc. (Hons.) Agricultural Sciences

Major
“Food Science and Technology”
DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY

UNIVERSITY OF AGRICULTURE, FAISALABAD, SUB CAMPUS
BUREWALA, VEHARI
2020
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ACKNOWLEDGMENT
Though words may never say what we want to, still there is the most appropriate way of
expressing emotions. I am, though, never be feeling able to offer my thanks to Almighty
Allah, the propitious, the sole creator of the universe, the source of all knowledge and
wisdom.
First of all, I would like to thank Allah Almighty who helped me a lot in all the hectic
moments of the internship. In hopeless moments my one and only Allah guided towards the
right direction.
I am very grateful to my loving Parents who motivated me during this process and whenever
I thought to give up they encouraged me a lot.
I feel highly privileged to record the deep sense of gratitude and sincerity for my supervisor
Mr. Riaz Ahmad (Director Production) and co-supervisor Madam Sana for his precious
suggestions, dedicated efforts, kind supervision, affectionate criticism and inspiring guidance
provided to me throughout the study, particularly in compiling my internship report.
I wish to record my sincere appreciation to my most respected and honorable principal Dr.
Sajid Mehmood Nadeem and teachers, Dr. M. Asif Khan, Ma’am Nadia Rehan, Ma’am
MadihaKhadim and Ma’am Zonia RashidDepartment of Food Science and Technology,
University of Agriculture, Faisalabad Sub campus Burewala, Vehari.
And I love to mention my brother and sisters who always encouraged me during that time. I
can never pay back the love of my family.
Friends always play a vital role in someone‟s success. Here I am cordially thankful to my
friends and fellows Sehrish Fatima, Aniqa Mushtaq, Sarfraz Ali and AbdulRehman
Mushtaq for their nice company and cooperation at Shezan International Limited, Lahore.
Thank you to the Shezan Workers Team for co-operating with us and guide us.
SEERAT SALEEM
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DEDICATED
This work, the efforts of my

Thoughts and study
TO
My Affectionate, loving
And
Graceful
PARENTS
Sweet, beloved and great
Mr. & Mrs. RAO. M. SALEEM
Whose love encourages me
At every step…
And
Also to my great and humble
TEACHERS
Dr. M. ASIF KHAN (HOD)
MADAM NADIA REHAN
Who appreciates and guide me
At every step…
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CERTIFICATION
To whom it may concern
It is certified by the supervisor that Ms. Seerat Saleem D/O Rao. M. Saleem Regd. No.
2016-ag-8260, student of B.Sc. (Hons.) Food Science and Technology, University of
Agriculture Faisalabad, Sub Campus Burewala, Vehari has completed an internship at Shezan
International Limited, Lahore from 19 Feb 2020 to 29 April 2020. The work and internship
report submitted by her have been found satisfactory and recommended that it can be
processed for evaluation by external exam for the award of degree B.Sc. (Hons.) FST.
INTERNSHIP SUPERVISORY COMMITTEE

PRINCIPAL/ PROJECT DIRECTOR:
_______________________________
DR. SAJID MEHMOOD NADEEM
Associate Professor (Dpt. SES)
Principal/ Project Director
UAF Sub-Campus Burewala, Vehari
EXTERNAL SUPERVISOR:
_______________________________
MR. RIAZ AHMED
Director Production
Shezan International Limited, Lahore
INTERNAL SUPERVISOR:
_______________________________
DR. AHSAN KHAN
Assistant Professor (Dpt. PBG)
UAF Sub-Campus Burewala, Vehari
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TABLE OF CONTENTS
Sr. No. Title Page No.
1.
Introduction to Shezan International Limited 07
2.
Tetra pak 11
3.
Bottling section 40
4.
Pickle section 52
5.
Consumer section 63
6.
Completion of report 89
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CHAPTER# 1
INTRODUCTION TO SHEZAN
INTERNATIONAL LIMITED
The Shezan International Limited was incorporated on May 30, 1964, as a Private Limited
Company. Shezan International Limited was conceived as a joint venture by the Shahnawaz
Group, Pakistan, and Alliance Industrial Development Corporation, the U.S.A. in 1964.
Shezan is the largest food processing unit having developed and installed the capacity to meet
the country's local as well as export needs.
In 1971, the Shahnawaz group purchased all the shares of Alliance Industrial Development
Corporation with the permission of the Government of Pakistan. In 1980-81, a separate unit
was installed in Karachi which now caters to Karachi, Sindh, and export demand. A “bottle
filling plant” was set in 1983 in Lahore, Punjab. An independent “Tetra Brik plant” was
commissioned in 1987. In the year 1990, it was decided to install a juice factory at the Hattar
in Khyber Pakhtunkhwa of Pakistan. The Head office of Shezan International is located at
Lahore, Pakistan.
In Canada, Target Foods is the authorized distributor for all Shezan Products & in England
CITI TRADERS UK LTD & IS TRADERS LTD are the authorized importer and
distributors. They carry all the import and distribution of quality Juices, Jams, Pickles,
Chutneys, Sauces, Syrups, and Squashes.
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Other Businesses under the supervision of Shahnawaz Group of Companies are:
 Shahnawaz (Pvt.) Limited

 Shezan International (Pvt.) Limited
 Shahtaj Sugar Mills (Pvt.) Limited
 Shahtaj Textile (Pvt.) Limited
 Hattar Food Products (Pvt.) Limited
 Nawazabad Farms
 Information Systems Associates Limited (ISA) COMSTAR
1.1. HISTORY:-
In 1943, the late Mr. Shahnawaz founded his business in Agra and Delhi. After the creation
of Pakistan in 1947, he moved his headquarters to Karachi. Relations were established with
some of the leading Agricultural, Industrial and Automotive manufacturers of the world for
import of their equipment. This led to the rapid expansion of the Company.
Today, the name SHAHNAWAZ stands for a successful group of Companies in Pakistan.
The network of Shahnawaz companies covers the whole country with full-fledged offices in
all principal cities, namely Karachi, Hyderabad, Lahore, Rawalpindi, Islamabad, Peshawar
and Quetta with dealers and sub-agencies in all major towns.
In 1952 before getting the worlds famous name „Shezan‟, the company initiated its business
in Lahore as a cold store which later on became the Asia‟s largest cold store in 1956 at that
time Shezan was just storing Fruits and Vegetables, but later on, after the development of a
new citrus strain the „Kino‟, the company also started producing Kino squash as a small food
processing unit but making this small Squash production unit a huge International Industry
required a huge revenue and investment; for this purpose the founder of the company Mr.
Muhammad Shahnawaz of Dist. Sialkot (The Founder of Shahnawaz Group of Companies)
made a contract with Alliance Industrial Development Corporation Company of United
States on 30th May 1964 and started producing its world-famous Mango Juice.
Later on, in 1971, Shahnawaz Group purchased the complete shares of the company. The
company has been steadily expanding its production capacity over the years. In 1980-81 a
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separate unit was installed in Karachi, which now caters to Karachi, Sindh, and export
demands.
A new bottle filling plant was set up in 1983 in the Lahore unit, increasing the capacity five-
folds, afterward in 1984Shahnawaz Group of industries sold out its shares in „Karachi Stock
Exchange Company‟ (KSEC). An independent Tetra Brick plant was commissioned in 1987
making the unit a leading manufacturer with a comprehensive range of products in the fruit
processing field in Pakistan.
The company is engaged in the manufacture and sale of Juices, Beverages, Pickles, Sauces,
Jams, Jellies, Marmalades & Vinegar preserves, and flavoring based upon or derived from
fresh fruits and vegetables.
1.2. MISSION:-
Our mission is to provide the highest quality fruits and vegetables related juices and products
to retail and foodservice customers. We want to be the recognized industry leader in quality
and service, providing more than expected for our customers, employees, and stakeholders.
We will accomplish this by maintaining a tradition of pride in our products, growth through
innovation, integrity in the management of our business, commitment to Team Management,
and the Quality Improvement Process.
1.3. VISION:-
To be known as the leader of quality products in the region. Dedication to quality is a way of
life at our Company. It is the objective of Shezan International Limited to produce and
provide products and services of the highest quality. In its activities, the Company will pursue
goals aimed at the achievement of quality excellence and succeed as a profitable business.
These results will be derived from the dedicated efforts of each employee in conjunction with
supportive participation from management at all levels of the Company.
1.4. ACHIEVEMENTS:-
 All Shezan products have been certified as 100% Halal.

 The products are certified under „HACCP‟ (Hazard analysis and critical control
points) which systematically protects food from damaging reactions that take
place in the environment.
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 The company received the ISO certifications; 9001-2008 and 22000-2005.
 Shezan also received the Quality Food Products certificate from the Rawalpindi
Chamber Of Commerce.
 The company was honored by the Karachi Stock Exchange when The Top
Companies Award was accepted, in 1994.
 We also received the prestigious Consumer Choice Award in 2013.
1.5. QUALITY ASSURANCE:-
Research and Development is one of the fundamentals of any company. Shezan is one of
those companies that give extra importance to this field. Here at Shezan, we do not shy away
from spending lavishly on the Research and Development Sector because along with taste, it
is also responsible for determining the hygiene of any food product and health and hygiene
are our foremost priorities. Also, Shezan aims to provide tasty food which is both wholesome
and nutritious!
The ingredients that are not available locally are imported. Most of the fruits and vegetables
are hand-picked from Shezan‟sorchards. These, along with other local and imported
ingredients are then taken to our state-of-the-art microbiology labs, where they are examined
and tested and the best quality ingredients are separated. The ingredients are creatively mixed
and developed into new flavors. Shezan sculptures these new flavors into innovative products
e.g. Shezan Twist which is a fusion of great flavors. Here at Shezan, hygiene is of utmost
importance. All ingredients are processed in such a way that their nutritional values are not
affected adversely. This ensures excellent quality and an impeccable taste, which is
characteristic of all Shezan products.
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CHAPTER#2
TETRA
PACK
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2.1. TETRA PAK:-
Tetra Pak is a multinational food packaging and processing company of Swedish origin with
head offices in Lund, Sweden, and Lausanne, Switzerland.
The company offers packaging solutions, filling machines and processing solutions for dairy,
beverages, cheese, ice-cream, and prepared food, including distribution tools like
accumulators, cap applicators, conveyors, crate packers, film wrappers, line controllers and
straw applicators.
Tetra Pak was founded by Ruben Rausing and built on innovation by „Erik Wallenberg‟,
the Tetrahedron packing, from which the company name was derived.
In the 1960s and 1970s the development of the Tetra Brik package and the aseptic packaging
technology made possible a cold chain supply, substantially facilitating distribution and
storage. From the beginning of the 1950s to the mid-1990s the company was headed by the
two sons of „Ruben Rausing‟, „Hans and Gad‟, who took the company from a family business
of 6 employees, in 1954, to a multinational corporation.
Tetra Pak is currently the largest food packaging company in the world by sales, operating in
more than 170 countries and with over 23,000 employees (2012). The company is privately
owned by the family of Gad Rausing through the Swiss-based holding company Tetra Laval,
which also includes the dairy farming equipment producer DeLaval and the PET
(Polyethylene Terephthalate) bottle manufacturer Sidel.
2.2. ASEPTIC PACKAGING:
Aseptic packaging is the process by which a sterile (aseptic) product (typically food or
pharmaceutical) is packaged in a sterile container in a way that maintains sterility and longer
shelf life.
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Aseptic packaging prevents microbes and bacteria from getting in once the package is
closed. This is a great advantage for food and drinks. Aseptic package must be tight so that
microbes and bacteria cannot get in from outside.
The diagram below illustrates the aseptic packaging process:
Sterility is achieved with a flash-heating process, temperature between 195° and 295°F (91°
to 146°C), which retains more nutrients and uses less energy than conventional sterilization
techniques such as retort or hot-fill canning. Sterile food processing includes the use of clean
rooms, bacteria retaining filters, dry or steam heat. Aseptic food preservation methods
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allow processed food to keep for long periods without preservatives, as long as they are not
opened.
The aseptic process flow chart is given below:
The aseptic packages are typically composed of paper board (75%), polyethylene (LDPE)
(20%), and aluminum(5%), with a tight polyethylene inside layer. Together these materials
form a tight seal against microbiological organisms, contaminants, and degradation,
eliminating the need for refrigeration.
The first aseptic filling plant for milk was presented in Switzerland in 1961. The Tetra
Pack company later became one of the leading suppliers of processing and packaging
equipment for dairies. Aseptic techniques were common in Europe and Asia before they were
introduced in the United States in the 1980s.
Feasibility of Aseptic Machine:
The aseptic filling machine should be provided with such a working environment that is
compatible with its aseptic design, features, and function. It means that there should not be
the possibility of contamination to enter into the aseptic product from the environment.
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Aseptic Process Mechanism:
The product which is to be filled in tetra pack, sterilized outside the package using Ultra-high
temperature process that rapidly heats and then cools the product before filling.
The available time and temperature range (generally 15 to 30 seconds and temperature 195°
to 285°F) allow the process to be tailored to produce the least amount of thermal stress effect
on the product while ensuring safety.
It is different and more beneficial from conventional methods because the Flash Heating and
Rapid Cooling aseptic process substantially reduce energy use and nutrient loss associated
with conventional sterilization.
As a result, aseptically processed food products retain a much higher nutritional value and
exhibit more natural texture, color, and taste. In juices, the heat treatment is done at 95-98°C
for 15-30 seconds.
Benefits of using aseptic packaging:
1. It extends the shelf life of products at normal temperatures by packaging them

aseptically.
2. Aseptic packaging enables containers to be used that are unsuitable for in-package
sterilization.
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The whole process of aseptic packaging is done in the machine known as “Automatic
splicing unit” (ASU).
2.3. PACKAGING MATERIAL:

Tetra Pak cartons are one of the most sustainable packages in existence today. Because tetra
pack cartons are made from a paper, which comes from wood, a renewable resource. The
packaging material protects the product inside the package from the environment outside.
It also needs to be firm enough to give the package a good shape. This is essential for
transport and handling. The packaging material is also printed with information about the
contents of the package.
PACKAGING MATERIAL LAYERS:-
The 6-Layered packaging material is the result of Tetra Pak‟s innovative technology. This
packaging material consists of paperboard, polyethylene, and aluminum.
FUNCTIONS AND PERCENTAGE:
The function and percentage of a different layer of Tetra Pak are given below:
 Polyethylene external layer:

1. 20% (Total percentage including all layers)
2. Waterproof.
3. Protect against outside (environmental) moisture.
 Paper board:
1. 75%
2. Provide stiffness, strength, and sustainability.
3. Stability and resistance of the package.
4. Maintains a distinct standard shape of the package.
 Polyethylene adhesive layer:
1. Lamination layer.
2. Creates a strong adhesion in Aluminum and paper layers.
3. Supports the function of paper by giving it strength.
4. Prevents moisture to reach paper.
 Aluminum foil:
1. 5%
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2. Barrier against external Oxygen, flavor, and light.
 Polyethylene layer:
1. Needed for the lamination process.
2. Adherence layer.
 Internal polyethylene layer:
1. Seals in the liquid.
2. Protection to the product.
The picture below describes what type of effects the different layers in the packaging material
protect against.
1. Outer coating.
2. Paper board.
3. Lamination.
4. Al- foil.
5. Internal coating 1
6. Internal coating 2.
7. Product
2.4. PASTEURIZATION OF JUICE:-
To pasteurize juice its flow rate through pasteurizer is adjusted to 15-30 seconds stay time in
a way, that juice may attain a temperature of 95-97°C. This time and temperature
combination is called „holding time‟; which is the time required to kill microorganisms.
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90oC ____
Temperature
Holding time Cooling time
15-30 seconds
Time
Balance Jar
Tetra Pak Pasteurizer at Shezan has a capacity of 3000L/hour, if the flow rate exceeds this
limit, the required time and temperature combination cannot be obtained and juice will not be
pasteurized. The Pasteurizing capacity of the pasteurizer should match the filling capacity of
the production machine; it should be at least 20% above the production capacity of the filling
machine to maintain the line pressure of the liquid in the system. The filling machine usually
operates at a speed of 7500 packets/hour.
In Shezan there are 4 different pasteurizer plants and have different capacities.
A. 7000 Liter
B. 3000 Liter
C. 3500 Liter
D. 1500 Liter
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In Shezan there are 4 different Tetra Pak plants, two of them have the same capacity while
two have different.
A. 250 ml (2)
B. 200 ml (1)
C. 1000 ml (1)
Shezan produces 3 flavors of juices:
i. Apple
ii. Mango
iii. Fruit Punch (Apple, Mango, Orange, Pineapple)
Although pasteurization temperature is kept 95-97°C even then both inlet and outlet
temperatures of pasteurizing machines are maintained at 32-36°C. Pasteurizer has four
sections of which 3 sections heat the juice and the final last section cools the juice. The
minimum holding temperature is 90°C it is also known as „diversion temperature‟. If it is
≤90°C, then the diversion valve gets opened and juice does not go to filling machine until and
unless the temperature becomes >90°C or above it.
Diversion Valve
RETURN 90oC<
PRODUCT MACHINE
>90oC
2.5. PLATE HEAT EXCHANGERS:-
It was first produced in the 1920s and has since been widely used in a great number of
sectors. A plate exchanger consists of a series of parallel plates that are placed one above the
other to allow the formation of a series of channels for fluids to flow between them.
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The space between two adjacent plates forms the channel in which the fluid flows. Inlet and
outlet holes at the corners of the plates allow hot and cold fluids through alternating channels
in the exchanger so that a plate is always in contact on one side with the hot fluid and the
other with the cold. The most frequently used materials for the plates are stainless steel (AISI
304, 316), titanium, and aluminum.
Hot water in Product out Hot product in Cool water in
Product in Hot water out Holding Tube Water out Cool Product Out
(35oC –40oC)
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2.6. STERILIZATION OF TETRA PAK CARTONS:- (Aseptic Packaging)
To Protect Juices for a long time, it is essential to sterilize Tetra Pak cartons and equipment to
make them free of micro-organisms. For this purpose, H2O2 is used which is a strong
oxidizing agent.
H2O2 and its free radical derivatives react with cell membrane lipids and proteins causing the
cell membrane to rupture. This mode of action is very effective in the killing of a wide range
of micro-organisms.
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An aseptic package has been sterilized before filling with UHT (Ultra High Temperature)
treated food, resulting in a product that is shelf-stable for over 6 months.
Our aseptic packaging method passes flat, unformed packaging material through a heated
hydrogen peroxide bath. A hydrogen peroxide concentration of 30% is heated at 70°C for six
seconds. Hydrogen peroxide is then eliminated from the packaging material using pressure
(squeezing) rollers or hot air.
The environment where food is handled and sealed must also be free of potentially
contaminating bacteria. That means filling and sealing machinery must be sterile before
packaging and during the production process. This can be achieved using hot air and steam or
by combining heat treatment with hydrogen peroxide chemical sterilization and takes 45
minutes.
Concentration and pressure of H2O2 should be regularly inspected during the production by
the instrument aerometer. If the concentration of H2O2 is below 30% or above 50% it should
be replaced with fresh H2O2. Packaging material will be sterilized with H2O2 at 65o to 70o for
6.6 seconds minimum.H2O2 concentration check after every 2 hours.
Precautions:
1. H2O2 can cause burns, eye damage and ingestion may be fatal.
2. When handling H2O2 always wear the proper personal protective equipment at all
times.
Storage:
H2O2 should be stored in a cool and dry place away from incompatible material.
Hot air (125oC)
Squeezing rollers (squeeze or

Sucks H2O2)
Water
75o-80oC
H2O2 (65o-70oC)
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HYDROGEN PEROXIDE CONCENTRATION CHECK:-
Equipment:
1. Aerometer/ Hydrometer (specific gravity meter)
2. Thermometer
3. Graduated plastic cylinder.
Caution:
The above-mentioned equipment should be perfectly cleaned. If H2O2 little concentration

remains in the tetra pack then it affects the juice taste, flavor, and also on the pack.
Procedure:
1. Open the valve of the H2O2 tank and draw out about 250mL of H2O2 from the tank
into a perfectly clean vessel (graduated cylinder).
2. Aerometer is placed in the cylinder so that the aerometer may float in the cylinder.
3. If there are air bubbles on the aerometer, stir gently until the bubbles disappear.
4. Read the density at the level of the liquid on the aerometer scale and at the same
time read the temperature.
5. Evaluate the H2O2 concentration from the label with the scale by comparing the
density value of the sample with the temperature value to obtain the H2O2
concentration.
2.7. JUICE FILLING MACHINE:-
After pasteurization of juice and sterilization of the tetra pak aseptic package, the next step is
juice filling. The pasteurized juice is passed through the pipes and floats towards the filling
machine. Here, the aseptic tetra package sheet changes into a pipe form and a tube fills the
juice inside it. Then the cutter cuts it into a tetra pack.
One side of this pack is sealed and the other is the plan. After cutting the four flaps corners
are also bend and the two flaps are attached at the upper section where a sealed hole with
aluminum foil is present for pipes and the remaining two flaps attached at the bottom. The
juice before comes to room temperature because the tetra pack cannot bear high temperature.
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While cutting the tetra packages cold waterfalls on them. After filling and packets cutting,
package moves on the conveyer and proceed for further processing.
2.8. PRINTING PROCESS:-
After the tetra packs filled with juice and move on the conveyer, the packets pass through the
printer. Here, the date, time, batch no., text, price prints on it.
2.9. STRAW MACHINE:-
After printing the package further move on the conveyer and pass through the straw
applicator and straws attached on it.
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2.10. PACKAGING OF JUICE:-
After straw attached to the package, then packaging done. The packaging at Shezan is done
manually. One juice package or tray contains 27 packs.
2.11. RAPPING MACHINE:-
After that, the tray move on the conveyor, and a machine cut the lamination sheet or film
wrapping and placed on the packet. The rapping machine contains a knife and an oven. When
the tray passes through the rapping machine the knife cuts the extra film wrapped or
lamination sheet and the oven milt the rap so that it paste on the package to protect the
package and make the carton feasible for transport and handling.
2.12. SEALS OF TETRA PACK:-
Any aseptic package or system must be capable of closing or sealing the package
hermetically to maintain sterility during handling and distribution.
There are three seals manufactured in the tetra pack system:
i. Longitudinal seal (L.S)

ii. Strip application side (S.A)
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iii. Transversal seal (T.S)
1. LONGITUDINAL SEAL (L.S):
In the longitudinal system, a flat web of the packaging material is used, supplied in reels.
This flat material web is formed into a tube, which is sealed longitudinally resulting in a
cylinder-shaped structure. The L.S seals the package along the long side.
In the tetra pack, along with the longitudinal seal, there are “Top longitudinal creases” and
“Bottom longitudinal creases”. These are the pre-formed folds in the packaging material.
They give the package its final square form.
The “Top fin” and “Bottom fin” is the area of the package where the package is sealed and
cut.
2. STRIP APPLICATION SIDE (S.A):
A Longitudinal seal strip of laminated plastic applied on the inside of the longitudinal seal.
It prevents the product from soaking into the edge of the packaging material. This strip is first
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sealed to one edge of the packaging material and once the packaging material tube has been
formed it sealed to the inner surface of the packaging material. Both these operations, the
strip application, and the actual longitudinal sealing are done by using sterile, hot air and
pressure.
The L.S strip is composed of different layers and has different utilization depending upon the
product and package type. This strip is formed of “Metalosine- Polyethylene- Metalosine”
(MPM).
3. TRANSVERSAL SEAL (T.S):
It seals the package at the top and the bottom. Transversal sealing is done below the level of
the product in the packaging material tube. By constantly moving sealing and pressure jaws,
the pressure is applied from the outside of the packaging material tube squeezing the product
from the sealing area.
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At the transversal seal, there are “Flaps” formed. Two flaps at the top and two flaps are at
the bottom. The top and bottom flaps are the corners of the package that are folded and
sealed to the packaged body.
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2.13. TESTS OF THE TETRA PACK SEALS:-
These tests must be performed during production. In Shezan these tests are done after every
30 minutes and 8 packages are checked through all the tests.
1. TRANSVERSAL SEAL TEST(T.S):
TEARING TEST
Take a tetra pack sample. Unfold the top and bottom flaps of the package. By gently
squeezing the package with the fingers check the package has product leakage or not from
the transversal seal.
Pour off all the juice in the bucket by cutting the top and bottom edges of the package. Rinse
the sample with water and dry it with compressed air. Cut off 1 mm maximum from the
edges.
After the fold, the cut sample and run your finger on the T.S and check if there are plastic
lumps or ridges. Then place the sample in the „stretch pliers‟ and gently stretch the
transversal seal.
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After placing the sample in the stretch plier, stretch by pressing the plier handles along the
whole length of the sample. Stretch a little bit at a time, from both ends towards the
longitudinal seal/ transversal seal cross. If the layers of the tetra pack are separate accurately
then the package is of good quality. This will enable us to be a better evaluation.
2. STRIP APPLICATION TEST(S.A):-
The seal can be either „good‟ or „defective‟. A seal is good when it is mechanically more
resistant than the packaging material. If a seal is defective, it could easily be caused
unsterility. The first sign of a good seal is stretched plastic film. Breakage in the aluminum
foil and paper board layers also shows that the seal is stronger than the packaging material.
GOOD SEAL
Take a tetra pack sample for the test. Unfold the top and bottom flap. Pour off all the juice in
the bucket by cutting the top and bottom edges of the package. Then cut the planning side
and save the seal side. Rinse the sample with water and dry it with compressed air. Cut off 1
mm maximum from the edges. Place the sample in the „stretch pliers‟ and gently stretch the
transversal seal. If the seal does not come apart; the plastic film stretches and breaks leaving
the paper board uncovered.
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“Good seal”
The case described above applies also to the cross, where T.S and L.S meet. The L.S must be
considered and additional plastic multi-layer.
3. LONGITUDINAL SEAL TEST (L.S):-
TEARING TEST
Take a tetra pack sample for the test. Unfold the top and bottom flaps.
Cut two opposite corners (top right and bottom left), empty the package content. Pour off all
the juice in the bucket. Cut the sample corner to corner in a diagonal, across the front panel of
the package leaving the L.S intact.
Open up the sample, rinse the sample with water, and dry it with compressed air.
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The quality of the seal is tested by tearing the L.S strip manually. The seal must be
mechanically stronger than the packaging material. If the sealing is good, the packaging
material layers (plastic film, Aluminium foil, or paper board) come apart together with the
strip.
4. DIA TEST:-
Take a tetra pack sample for the test. Unfold the flaps of the packaging sample. Don not
stress or flatten the sample.
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Cut two opposite corners (top right and bottom left), empty the package content. Pour off all
the juice in the bucket. Cut the sample corner to corner in a diagonal, across the front panel of
the package leaving the L.S intact.
Open up the sample, rinse the sample with water, and dry it with compressed air.
Make an oblique cut across the longitudinal seal.
Now, inject 1 ml of red ink into the air channel or strip of the L.S with 1 ml syringe. The
needle should be around 0.4-0.5 mm to get into the air channel. Evaluation can be done by
applying red ink on the inside the package or outside the L.S strip.
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Leave the sample to dry and remove the excess of red ink before looking for leakages. If the
red ink flows straight in the air channel then the seal is good and the package is clear. If the
red ink in the air channel spreads then the seal is defective and the package is also defective.
“Defective
Seal.” “Good Seal.”
5. CONNECTIVITY TEST:-
Select a suitable number of packages according to the level of accuracy needed. Cut the
package into two halves with a cutter, do not cut the seal side, only the top parts will be used
for the test.
Rinse the package sample with water. Then pour water in one cut half and placed it in the
water tub. An instrument known as “DC MicroAmpere Meter” is used to detect the pinhole
in the tetra pack. Place the sample pack in the water tub then, insert one rod of the instrument
in the pack and one rod in the water tub. If there is a pinhole present then the needle of the
meter moves and the package is defected and rejected. If the needle does not move then the
package is good.
2.14. ONLINE QUALITY CHECKS AND THEIR PROCEDURES:-
BRIX:
Brix of a product is the measure of total soluble solids present in that product. Brix of a
product is measured through a Refractometer (Refractometer measures the refractive index
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of substance which depends on the density of a substance) as the sugar percentage in liquid
affects its density so the refractive index of a juice is also affected in the same pattern.
 Brix of Mango fruit drink we checked at Shezan is 11oBx.
ACIDITY:
The acidity of a product is the measure of % of acid present in that product.
To check the acidity titration method is used. For acidity checking, we perform titration(a
technique where the solution of known concentration is used to determine the concentration
of an unknown solution)
Requirements:
a. Beaker ( 250 ml)
b. Juice
c. Water
d. Pipette (10 ml)
e. Phenolphthalein ( indicator)
f. NaOH ( endpoint) required to change the color of the indicator.
Procedure:
i. Firstly, take 250 ml beaker.
ii. Pour 10 ml juice in the beaker.
iii. Then add 100-150 ml water in it.
iv. Add 2 drops of phenolphthalein indicator.
v. Add drop by drop NaOH endpoint, until light pink color appears.
vi. Stop the titration when the pink color appears.
vii. Note down the reading of NaOH used.
.
Calculated reading of NaOH used:0.9 reading of NaOH.
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pH:
The pH of the product is the measure that is the product acidic, neutral, or basic.
pH is usually checked through pH meter, but usually, pH paper strips are preferred because
of their quick action speed and no need for calibration and washing.
H2O2:
Aerometer/ Hydrometeris used to check H2O2Concentration.
CIP of the plant and the filling machine is performed at least after 24 hours of the
continuous production or in-case of violation of aseptic conditions during the production.
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2.15. CLEANING IN PLACE:-
Cleaning in place is a chemical cleaning method in which the food processing machine is
cleaned without dismantling its various parts. All the parts are cleaned at their relevant places
without displacing them. This type of cleaning is highly beneficial as the cleaning liquid is
circulated in the different parts of a closed system. This results in better cleaning with less
use of cleaning liquid and less wear and tear of different parts of the machine.
CIP of the plant and the filling machine is performed at least after 24 hours of the continuous
production or in-case of violation of aseptic conditions during the production.
CIP CONTROL PANNEL
Method of CIP (cleaning in place):
CIP of the system is carried out according to the schedule (TBA-F-01 and TBA-F-02) a
routine process in food processing industries generally done after the production.
CIP Parameters:
1. Liquid temperature
2. Liquid pressure
3. Chemical strength
4. The flow rate of liquid
5. Circulation time of the liquid
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All the parameters should be according to the CIP schedule. It is very essential before the
start of the new production. Otherwise, bacteria and other microbes will produce and spoil the
whole production.
CIP equipment:
1- SS- centrifugal pump, capacity> 8000 liters/hour, pressure = 4-5 bar

2- SS- tanks, capacity 150 liter
3- Thermometer
Steps in CIP:
1. Raw water (For sugar removal)

2. Caustic soda (Alkali-For removal of fats and proteins)
3. Hot water (For removal of caustic soda)
4. Nitric acid (For removal of salts and minerals)
5. Raw water (For neutralization)
CIP procedure:
1. First of all the system (filler, pipelines, and pasteurizers) is flushed or rinsed by water
at ambient temperature (32-36°C) for 5 minutes. This will loosen all the residues of
the product which have been stuck to the walls of the pipeline.
2. Then hot water at 50-60°C is circulated throughout the system for 10 minutes. This
removes away all the leftover residues from the pipeline.
3. Then caustic solution (NaOH solution) of concentration 1.5-2% is circulated at 85-
90oC for 30 minutes for the removal of fats and proteins.
4. After this water at ambient temperature is circulated throughout the system again for
10 minutes.
5. Then Nitric Acid solution 0.75% -1.0% is circulated through the pipes at a
temperature of 70-75oC for 20 minutes.
6. At last, the pipes are finally rinsed with water at ambient temperature. This is done to
remove the residues of the cleaning liquids (caustic soda and nitric acid).
PUMPS USED IN CIP:-
There are 3 types of pumps used in CIP:
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a. Hot water pump.
b. Cool water pump.
c. Production pump.
Hot Water Pump

Cooling Pump
Production
Pump
Advantages of CIP:-
 Cost-effective as the cleaning liquid is circulated in the closed system (uses less
amount of cleaning liquid).
 Less risk of contamination as being a closed system.
 Less wear and tear of the machine parts.
 No need of dismantling the parts of the machine.
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CHAPTER# 3
BOTTLING
SECTION
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3.1. BOTTLING SECTION:-
Bottling lines are production lines that fill a product, generally a beverage, into bottles on a
large scale. Many prepared foods are also bottled, such as sauces, syrups, marinades, oils,
and vinegar.
The blended juice stored in SS-tanks is transferred from the blending section via the SS-pipe
system. It is then passed through the plate type heat exchangers for pasteurization at 96°C
and then fed to the bottle filler for onward production.
3.2. STEPS IN BOTTLING PLANT:
The bottling plant has the following parts/steps:
 Unloading or empty feed conveyor

 Roller conveyor
 Sorting of bottles
 Un caser machine
 Belt conveyor (Pick up a bottle from the shell)
 Shell move conveyor
 Un caser conveyor
 Un caser inspection light
 Bottle conveyor
 Bottle washer or washer feed conveyor
 Washer dams
 Total of 360 carriers. 1 carrier contains 32 bottles.
i. Washer tank 1: Caustic soda 3% to 4% and temperature 50o-70oC
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ii.Washer tank 2: Caustic soda 3% to 4% and temperature 70o-80oC
iii. Washer tank 3: Caustic soda 3% to 4% and temperature 70o-80o C
iv. Washer tank 4: Caustic soda 1% to 2% and temperature 70o-80oC
v. Washer tank 5: Treated water and temperature 75o-85oC
Water treated with resin chemicals. Phosphoric acid used with treated water.
 Water station (for removing of caustic soda and acid)
 Water discharge conveyor
 In one minute, 500 bottle discharge from the washer.
 The empty bottle inspection station
 Filler feed conveyor
 Control box or panel
 Bottle filler
 Total of 50 valves
 Speed 400 bottles per minute
 Magnetic belt conveyor (lift up crowns)
 Hoppers
 Crowner (total of 10 heads)
 Filler discharge conveyor
 Juice pasteurizer
i.Plate heat exchanger
 Juice directly heated with water, not steam.
 Temperature set point 88oC
ii.Diversion valve
 The filled bottle inspection station
 Printer/ Inkjet coder (date print, batch no, text, manufacturing or expiry date)
 Hot water bottle shower conveyor
 Table/ casing conveyor
 Roller conveyor
 1 pallet contains 50 crates and 1 crate contains 24 bottles
 Stacking
 Storage
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UNLOADING OR EMPTY FEED CONVEYOR:-
Empty bottles (new or used) are unloaded from the pallets and are placed on the moving
conveyor.
ROLLER CONVEYOR:-
The empty bottles within crates then further proceed on the roller conveyor for sorting, so
that bottles further inspected.
SORTING OF BOTTLES:-
Manual sorting of bottles is done while moving in crates on the conveyer. Broken, damaged
and bottles of other companies are separated (taken out). Straws from the bottles are removed
manually.
UN-CASER MACHINE:-
The un-caser machine takes out the bottles from the crates and places them on the bottle
conveyor. The empty crates are taken to the table conveyor.
BELT CONVEYOR:
The belt conveyor then picks up the bottles from the shell.
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 SHELL MOVE CONVEYOR:
The empty bottles when picked by the belt conveyor then their shells moved on shell
move conveyor and reached the point where packaging is done again.
BOTTLE CONVEYOR:-
The bottles are automatically placed on the bottle conveyer from the un-caser machine. The
bottles are aligned on the bottles conveyer from where they are inspected by a person who
takes out straws from the bottles of any damaged bottles. The bottle conveyor takes the
bottles to the bottle washing machine.
“Sodium alkyl benzyl sulphonic acid” or “Calgonet BendfitEE” is used as a foaming agent to
reduce the friction of the conveyor components or for conveyor lubrication and make the
movement of bottles easy on the conveyer.
BOTTLE WASHER FEED CONVEYOR:-
The washing of bottles takes place in the bottle washing machine. This washing is of two
types which are:
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JET WASHING:
Pre-rinse jet washing: Before entering the washing tank, the bottles are sprayed with hot
water coming from hot water jets present above the bottles moving in the bottle conveyor.
Pre-rinse jet starting from the water tank 1st and ends on water tank 3rd.
Caustic-jet washing: Before entering the next tank each time the bottles are washed with the
caustic solution coming from caustic jets.
Caustic jets started from the water tank 4th and ends on water tank 5th.
WASHER DAMS:-
Dip- the washing of bottles takes place in all tanks with the gradual rise in temperature.
Total 360 carriers in the washer dam and one carrier contain 32 bottles.
“Treated water” is that water which is treated with resin chemical. Phosphorous acid is used
with treated water. Treated water is used at a temperature of 75o to 85oC in the tank no. 5th.
Tank No. Washer Spec. Temperature

1st Tank 3-4% caustic 50o-70°C
2nd Tank 3-4% caustic 70o-80°C
3rd Tank 3-4% caustic 70o-80°C
4th Tank 3-4% caustic 70o-80°C
5th Tank Treated Water 75o-85°C
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WATER STATION:-
This is the last part of the washing machine. In this section 8 bottles are washed at a time and
each bottle is washed 8 times with high-pressure soft water (treated water from softening
plant) jets at a temperature of 75-85°C. This cleans out all the caustic residues, acid, and
other foreign particles present in as well as out the bottles.
“Treated water” is the water that is treated with a Resin chemical. Phosphorous acid used
with treated water.
WASHER DISCHARGE CONVEYOR:-
This process can be done when the empty bottles are washed through caustic soda and treated
water and after that passing through the water station. In one minute, 500 bottles discharge
from the washer.
EMPTY BOTTLE INSPECTION LIGHT:-
After washing the bottles are again placed automatically on the bottle conveyor from where
they pass in front of the screen with the florescent light in it. This can be done before filling.
A group of 2-3 peoples inspects the washed bottles and separates the unwashed or improperly
washed bottles or separates the bottles that have un-cleaned tags/ monograms.
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FILLER FEED CONVEYOR:-
The filler feed conveyor carries the empty washed bottles to the filling machine. The filler
feed conveyor has a total of 50 valves.
After all this process, Shezan workers took up or collected 8 bottles randomly every 30
minutes to check the caustic residues.
„Phenolphthalein‟ indicator is used to check the caustic soda. „Methyl orange‟ is used as an
indicator to check the residues of phosphoric acid.
The food-grade used is SS-316.
CONTROL BOX/ PANEL:-
It controls the speed of the filling and machine. The maximum number of bottles that can be
filled is 600 bottles/minute, but it has been adjusted to 400 bottles/minute.
JUICE PASTEURIZER:-
The juice coming from the blending hall is taken to the pasteurizer where it is pasteurized at
85-95°C and the juice is then immediately filled in bottles by filling machine. There is also a
balance tank that lets only a controlled amount of juice to go in the pasteurizer. The
temperature recorder records the temperature.
PLATE HEAT EXCHANGERS:
This juice is directly heated with water not with steam because steam creates bubbling on the
top of the juice and also the effect on taste. The temperature set point is 88oC.
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DIVERSION VALVE:
If the juice temperature is below 88oC, then the diversion valve rejected the juice and
sending back to the pasteurizer. If the juice temperature is 88oC or above then the diversion
valve passes the juice to the filling machine.
BOTTLE FILLER:-
Mitsubishi filler crowner is used. Juice from pasteurizer comes to filler machine and bottles
from filler feed conveyors are automatically inserted in the filler. The filling valves are
opened and fill the bottles with juice up to the mark.
There are pistons on the lower side of the filler that control the opening of the valves for juice
filling and release of bottles from the Filler. Filler machine fills the bottles by pressure filling
so that vacuum is created in the bottle.
Juice temperature is 80o to 90oC, waterfalls on the valves of filler to maintain the temperature
of the valve, and for cooling of the valve. Juice temperature is set at 80o-90oC. Waterfalls on
its valve to maintain the temperature of the valve and for cooling it, so, that it does not
rupture.
MAGNETIC BELT CONVEYOR:-
In the hopper, crowns are placed. Then a magnetic belt lifts the crowns and passes towards
the crowner.
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“Magnetic belt conveyor”
CROWNER:-
After filling, the bottles immediately come from valves and go to crowner for crowning. A
magnetic belt continuously supplies the crowns from the crown hopper. The crowner has a
total of 10 heads.
FILLER DISCHARGE CONVEYOR:-
After the crowning, the bottles move on a discharge conveyor where further inspection is
done.
FILLED BOTTLE INSPECTION STATION:-
After filling and crowning the bottles are manually inspected by the workers while the bottles
are passing through a light screen. The empty, low filled, uncrowned bottles or bottles with
any unwanted material or with un-cleaned monograms are separated here.
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INKJET CODER/ PRINTER:-
The inkjet coder or printer with electronic sensors codes the production date, expiry date;
batch no, texts on the bottle crown.
The expiry date of the bottle is 6 months.
BOTTLE SHOWER CONVEYOR:-
Warm water is used as the cleaning agent for filled bottles to remove the foreign particles or
the juice residues stuck to the bottle surface.
TABLE/ CASING CONVEYOR:-
The filled, coded and washed bottles are placed in the crates (24 bottles/crate) manually.
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ROLLER CONVEYOR:-
When the bottles are placed in the crates, then the bottles proceed on the roller conveyor for
stacking.
STACKING AND STORAGE:-
These crates are then stacked on the pallets and taken to the storage palaces by the lifters.
 One pallet contains 50 crates. One crate contains 24 bottles.

 The bottle capacity is 240 ml.
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CHAPTER# 4
PICKLE SECTION
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4.1. PICKLE:
A relish consisting of vegetables or fruit preserved in vinegar or brine. In different regions,

pickles are known with different names and are as follows:
1. Pickles, a name for a pickled cucumber in the United States and Canada.
2. Pickle, a sweet, vinegary pickled chutney popular in Britain, such as Branston Pickle,
also known as "sweet pickle" or "ploughman's pickle"
3. South Asian pickles, also known as “achar”, any of several savory condiments
popular in South Asia.
4.2. PICKLING:
The process of preserving or extending the shelf life of food by either anaerobic fermentation
in brine or immersion in vinegar. In East Asia, “vinaigrette” (vegetable oil and vinegar) is
also used as a pickling medium.
In Shezan, 2 types of pickle prepare:
1. Pickle in oil. (Annual production of more than 95%)

2. Pickle in vinegar.
Mix vegetable
Lime pickle pickle in vinegar.
in oil.
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Major pickle of Shezan is “Strangachar” (mix pickle)
4.3. PURCHASE OF RAW MATERIAL:-
At the peak/ crop season (harvesting time) raw material is purchased, preserved, and stored.
The quantity of the raw material is stored according to the marketing sales target.
i. At harvesting time, vegetables have high nutritional value and have low prices.
ii. Mango peak harvesting time is “June and July”.
iii. Carrot, Horseradish, and turnip purchased in “December and January”.
iv. Lemon and Gum berry (Lasora) in “May”.
4.4. RAW MATERIAL:-
Shezan added 7 vegetables in a pickle. The raw material used for making pickles includes
mango, green chilies, lime, carrots, horseradish, gum berry (lasora), and cauliflower.
Spices include turmeric, red chili, cumin (zeera) seeds, fennel (saunf) seeds, carom (ajwain)
seeds, fenugreek (maithidana) seeds, coriander, nigella (kalonji) seeds, and mustard seeds.
Besides, Shezan adds table salt and canola oil. Shezan used canola oil because it is beneficial
for human health and is less saturated oil, high-density lipoprotein (cholesterol) and the
smoke point is above 200oC.
All raw materials are purchased from different parts of the country. Each raw material can
either be mixed or used separately for pickle production.
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4.5. PRESERVATION OF RAW MATERIAL:-
PRESERVATION OF MANGO:
“Raw mango”
Reception and sorting of raw mangoes:
Mangoes from different parts of the country are purchased and received in the industry.
After reception sorting of raw material is done manually. Over-ripe and damaged or infected
mangoes are discarded. Sometimes cut mango is purchased.
Washing:
After sorting the mangoes are washed in water having caustic soda. This washing is followed
by neutralization washing which is done in water having acetic acid.
Cutting:
Each mango is cut into four pieces (quarters). The stones are removed after cutting.
Dry salting:
Salting is done by adding NaCl or brine solution in a rotary drum machine containing mango
pieces that ensure uniform application of salt to mangoes. NaCl acts as a preservative.
Overnight stay:
After salting the mango pieces are allowed to stay overnight. This extracts out water from the
mango pieces and thus reduces the water activity. The water expelled out of the material is
drained.
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Brining and storage:
Brining is done in barrels or underground storage bins.
PRESERVATION OF GREEN CHILLIES:-
“Green chilies”
Reception and sorting of raw material:
Chilies from different areas are received. Infected and over ripped chilies are separated. The
leaves are separated and the chilies in bunches are separated into individual chilies.
Washing:
Washing of chilies is done in raw water.
Brining and storage:
Chilies are dipped in brine solution by placing them in bags of muslin cloth.
PRESERVATION OF LIME:-
“Lemons
”
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The lemons are received and sorted. The green and yellow lemons are separated from each
other. Spotted and infested lemons are separated.
Washing:
Washing is done to remove unwanted particles.
Brining:
Brining of lime is done in brine solution of required concentration.
PRESERVATION OF CARROT AND HORSERADISH:-
“Carrots”
“Horse-radish”
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Reception of raw material:
The raw material is received in the industry from different areas.
Peeling and cutting:
Peeling is done with the help of an abrasive peeler. After peeling them (carrot and
horseradish) are cut into finger-like pieces by the use of sharp knives.
Dry salting and overnight stay:
Salting is done by adding salt to the cuttings and mixing is done. Then it is allowed to stay
overnight to drain out water.
Brining:
Brining is done by dipping the cuttings in brine solution of required concentration.
PRESERVATION OF CAULIFLOWER:-
“Cauliflower”
Reception of raw material:
The raw material is received at the industry.
Washing and cutting:
After reception washing of cauliflower is done in raw water which is followed by cutting.
Brining:
Brining is done by brine solution of required concentration and acetic acid solution.
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PRESERVATION OF GUM BERRY:-
“Gum berry”
(Lasora)
The raw material is received at the factory and the infested or over and under ripped berry
gold is separated.
Washing:
Washing is done in raw water.
Salting and overnight stay:
Salting is done by adding salt to it. And then the material is allowed to stay overnight this
expels out water from the fruit.
Brining:
Brining of material is done in brine solution of required concentration.
De-capping:
The caps are removed from the fruits.
Vegetables are preserved for almost 1 year.

4.6. PRICKLE PRODUCTION:-
Types of a pickle:
There are two types of pickle produce at Shezan:
1. Pickle in oil
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2. Pickle in vinegar
Pickle in oil:
 Garlic pickle
 Mixed pickle Hyderabadi
 Mango pickle
 Lime pickle
 Green chili pickle
 Green chili and lime pickle
 Satrang pickle
 Berry gold pickle
 Mango kasondi pickle (peeled mango pieces)
“Pickle in oil”
MIXED PICKLE IN OIL:-
Ingredients:
i. Mangoes in quarters
ii. Lime (full)
iii. Green chilies (full without cut)
iv. Carrot and horseradish (cuttings)
v. Gum berry (full)
vi. Cauliflower (pieces)
vii. Salt
viii. Spices
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ix. Acid (citric acid and acetic acid)
x. Oil.
Procedure:
Washing:
The washing of the preserved raw material is done to remove the maximum salt contents and
contaminants if any. The chilies are sorted again to remove the spoiled chilies.
Frying:
The frying is done in pre-heated oil. The quantity of oil should be enough to fry (1/4 of the
frying pan). Different raw materials require different frying time.
 Mango 4-5minutes.
 Green chilies and lime require 1 minute or less.
 Gum berry, horseradish, and carrot require (10-15 minutes).
Purpose of frying:
 Softening of the tissues.

 To inactivate the enzymes.
 To reduce the microbiological load (Halophytes).
Citric acid and spices are added during frying. Acetic acid is added at the end of frying.
Overnight stay:
The fried material is allowed to stay overnight. The whole material should be fully dipped in
the oil. This is done for taste development.
Filling:
The filling is of following types:
Jar Filling:
 Pour oil in the jar (1/8 of the jar)

 Prepared pickle material is added to the jar.
 Pickle in the jar is pressed to remove air and dip the material properly in the oil to
avoid spoilage.
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 Capping.
 The capped jars are washed with hot water (mechanically) and then cleaned with a
towel (manually).
 Labeling is done manually.
 The jars are passed through a shrink wrapping machine for sealing.
 Jars are packed in cartons.
“Jar filling”
Pouch packing:
It includes the following steps
 Pickle is added in the pouches (poly bags).

 Oil is added to the pouches.
 Expelling the air and sealing the pouches.
 Poly packs are placed in plastic jars.
 Capping of plastic jars.
 Labeling.
 Shrinkwrapping of the jars.
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PICKLE IN VINEGAR:-
“Pickle in vinegar”
Ingredients:
 Green chilies are sorted.

 Limes are used as such.
 Ginger is cut in small pieces.
 No cooking and no spice addition.
Procedure:
 Add preserved material to the jar and add vinegar in it.

 Vinegar is drained out by inverting the jar while closing its opening with hand
(rinsing with vinegar).
 Vinegar is added again to the jar.
 Capping off the jar manually.
 Washing with hot water.
 Labeling (manually).
 Sealing by shrink wrap machine.
4.6. PACKAGING SIZES:
Shezan produces pickle in oil of Mango, Mixed, Cordiya Myxa (Berry Gold), Lime & Chili,
Lime, Mango Kasondy, Chili and Garlic in the packaging of 350 grams glass jar. Its 1
carton contains 12 jars.
Shezan has pickle in oil of Mango, Mixed & Cordiya Myxa (Berry Gold) in packaging sizes
of 1 KG plastic jar or bucket. Its 1 carton contains 12 jars or buckets.
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Shezan has pickle in the vinegar of Mixed Vegetable, Lime & Chili, Chili, and Lime in
packaging size of 300 grams glass jar. Its 1 carton contains 12 jars.
“Hyderabadi “Mango pickle

pickle in oil 350 in oil 350 grams
grams glass jar” glass jar”
“Satrang 1 kg “Satrang 1 kg
plastic jar” plastic bucket”
“Mix vegetable
“Satrang 500 pickle in vinegar
grams plastic 300 grams glass
pouch” bottle”
“Chili pickle in
vinegar 300
grams glass jar”
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CHAPTER# 5
CONSUMER
SECTION
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5.1. CONSUMER SECTION:-
In this section, jams, ketchup, sauces, vinegar, and squashes are produced.
5.2. KETCHUP AND SAUCES:-
Shezan prepares ketchup and different types of sauces. The names are given below:
1. Tomato ketchup
2. Chili garlic sauce
3. Ginger garlic chili sauce
4. Hot chili sauce
5. Soya sauce
6. Vinegar white
7. Vinegar brown
8. Green chili sauce
5.3. TOMATO KETCHUP PREPARATION:-
Ingredients:
 Tomato paste
 Sugar
 Sodium benzoate (preservative to increase shelf life)
 Color
 Spices
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 Onion
 Salt
 Citric acid
 Glacial acetic acid (99.9% acetic acid)
 Xanthan gum (used for ketchup thickening)
Procedure:
1. Clean the double jacketed stainless cooking pans.

2. Add tomato paste in the cooking pan and turn on the agitator.
3. Open the steam valve of the pan and add sugar according to the recipe.
4. Add extract of spices (which contains salt and onion extract) in the pan (The extract is
prepared by adding the blend of all spices, salt, and onion in the other pan and boiling
this blend for 40-45 minutes at the boiling temperature. This material is then filtered
to get the extract of the spice).
5. Now cook the material in the pan is for 3 minutes at a temperature at about 105°C-
110°C and the pressure of nearly 40 bars but not exceeding 40 bars to get 38° Brix
tomato ketchup.
6. Just before ending the cooking add color and preservatives by dissolving in water.
7. At the end of cooking add citric acid and glacial acetic acid.
8. Cool the ketchup by running water around the pan.
9. Pump the prepared ketchup to the filling the tank.
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10. The filling is done by vacuum filling machine in case of bottle filling and for bucket
filling ketchup is first to fill in the polythene bag which is then sealed and packed.
11. The bucket is then passed through a shrink wrapping machine while the glass bottle is
capped by the capping machine.
12. Then labeling is done manually on buckets and mechanically on glass bottles showing
the name of product, ingredients, and expiry date.
 In Shezan, total of 9 machines of 10 g tomato ketchup works and the machine is
“10gram machine”, temperature variations different in all.
a. 10-gram machine produces 10 g tomato ketchup packets (sachet). In one minute,

20-25 packets prepare. Temperature ranges from 64o-68o. Vertical heater
temperature ranges from 215o-218oC and bottom heater temperature ranges from
250o-260oC. An increase in temperature may also occur. The baking temperature
of tomato ketchup is 60oC and the time taken is 30-45 minutes. After sealing of
packets from sides, filling done through tubes. 1 transparent packet contains a
minimum of 96 or maximum of 100 packets.
“10 g machine”
b. 1 kg to 500 kg machine, have temperature ranges from 162oC, and heater

temperature ranges from 166oC. The packets are sterilized. The weight of the
empty packet is 14 g. The worker blows air in the packet, then pass on the
conveyer. After that ketchup fills in it and manually capping is done.
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“1 kg packet” “500 kg packet”
 Shelf life is 1 year of tomato ketchup.

c. 250 g machine heater temperature ranges from 145oC
“250 grams packet”
5.4. ONLINE QUALITY CHECK AND THEIR PROCEDURES:-

The acidity and Brix of ketchup are checked when 1 batch is completed.
BRIX:
Brix of a product is the measure of total soluble solids present in that product.
Brix of a product is measured through Refractometer (Refractometer measures the refractive

index of substance which depends on the density of a substance) as the sugar percentage in a
liquid effect its density so the refractive index of ketchup is also affected in the same pattern.
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The Brix of Shezan tomato ketchup is 28 according to standard.
ACIDITY:
To check the acidity titration method is used. For acidity checking, we perform titration (a
Requirements:
a. Beaker (250 ml)
b. Ketchup
c. Water
d. Pipette (10 ml)
e. Phenolphthalein (indicator)
f. NaOH (endpoint) required to change the color of the indicator.
Procedure:

ii. Add 2-gram sample of ketchup.
iii. After that add 150 ml water in it.
v. Add drop by drop NaOH endpoint, until color changes.
vi. Stop titration when pink color appears.
Calculated reading of NaOH used: 1.4 ml of NaOH used
70 | P a g e
5.5. PACKAGING SIZES:-
There are following different packaging sizes of ketchup at Shezan.
i. 10 g sachet (sashy)
ii. 100 g sachet
iii. 250 g sachet
iv. 500 g sachet
v. 1000 g sachet
vi. 6 kg of plastic bucket
vii. Standard size glass bottle 300 g
viii. King size glass bottle 830 g
ix. 1.8 kg of plastic bucket
x. 4 kg plastic gallon
“King size “1.8 kg Plastic

glass bottle” bucket”
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“4 kg plastic
gallon” “500 g
packet”
“1 kg packet” “250 grams

packet”
5.6. SAUCES:-
Sauces prepared at shezan are in different flavors and their names are as follows:
i. Chilli garlic sauce

ii. Ginger garlic chili tomato sauce
iii. Hot chili sauce
iv. Soya sauce
v. Green chili sauce
Shezan prepares vinegar of two types:
i. Vinegar white
ii. Vinegar brown
The production of sauces of all types and vinegar are closed at that time. But the workers of
the consumer section tell us about the ingredients, preservatives, and stabilizers used in all of
the sauces and vinegar.
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1. GINGER GARLIC CHILLI TOMATO SAUCE:
At the time of our internship, the production of ginger garlic chili tomato sauce is closed.
But the workers in the consumer section tell us about the ingredients used. We perform the
quality tests of the already preserved sauce.
Ingredients
i. Sugar
ii. Tomato
iii. Carrot
iv. Garlic
v. Red chili
vi. Salt
vii. Acetic acid
viii. Ginger
ix. Citric acid
x. Stabilizer (E-412)
xi. Preservative (E-211)
“Ginger garlic
chilli tomato
sauce”
5.7. ONLINE QUALITY CHECK AND THEIR PROCEDURE:-
BRIX:
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liquid affects its density so the refractive index of a juice is also affected in the same pattern.
 The brix of ginger garlic chili tomato sauce is 38oBx.

2. CHILLI GARLIC TOMATO SAUCE:
At the time of our internship, the production of ginger garlic chili tomato sauce is closed.
But the workers in the consumer section tell us about the ingredients used. We perform the
quality tests of the already preserved sauce.
Ingredients
i. Tomatoes
ii. Sugar
iii. Garlic
iv. Red Chilies
v. Salt
vi. Onion
vii. Acetic Acid
viii. Citric Acid
ix. Stabilizer (E-415)
x. Spices
xi. Preservative (E-211)
xii. Food Colors (E-110 & E-122).
74 | P a g e
“Chilli garlic sauce”
ONLINE QUALITY CHECK AND THEIR PROCEDURE:-
BRIX:
The brix of chili garlic sauce, we checked at Shezan is 34oBx.
3. GREEN CHILLI SAUCE:
BRIX:
The brix of green chili sauce is 11.6oBx.
ACIDITY:
technique where the solution of known concentration is used to determine the
concentration of an unknown solution).
Requirements:
a. Beaker (250 ml)
75 | P a g e
b. Green chili sauce
c. Water
d. Pipette (10 ml)
Procedure:
ii. Add a 2 ml sample of green chili sauce.
Calculated reading of NaOH used: 1.5-1.6 ml of NaOH used
4. SOYA SAUCE:
 Soya sauce has a shelf life of 3 years.
BRIX:
The brix of soya sauce, we checked at Shezan is 21oBx.
ACIDITY:
technique where the solution of known concentration is used to determine the
concentration of an unknown solution)
76 | P a g e
Requirements:
a. Beaker (250 ml)
b. Soya sauce
c. Water
d. Pipette (10 ml)
Procedure:
ii. Add a 2 ml sample of soya sauce.
There are following different packaging sizes of sauces at Shezan.
i. 10 g sachet
ii. 100 g sachet
iii. 250 g sachet
iv. 500 g sachet
v. 1000 g sachet
vi. 6 kg of plastic bucket
vii. Standard size glass bottle 300 grams
viii. King size glass bottle 830 grams
ix. 1.8 kg of plastic bucket
x. 4 kg plastic gallon
5.9. VINEGAR:-
Shezan prepares two types of vinegar.
1. Vinegar white
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2. Vinegar brown
“Synthetic
vinegar brown”
“Synthetic Vinegar
white”
 Vinegar has a shelf life of 3 years.

5.10. ONLINE QUALITY CHECK AND THEIR PROCEDURE:-
BRIX:
Vinegar has no brix.
ACIDITY:
Requirements:
a. Beaker (250 ml)
b. Vinegar white
c. Water
d. Pipette (10 ml)
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Procedure:
ii. Add a 2 ml sample of vinegar white.
PACKAGING SIZES:-
For vinegar and soya sauce, Shezan has following different packaging sizes.
a. 400 ml PET bottles

b. 800 ml PET bottles
c. 3.850 PET bottles
d. 4 kg plastic gallon
5.11. FRUIT JAMS:-
Shezan prepared 5 different fruit flavors jam.
1. Apple jam
2. Mango jam
3. Mix fruit jam (peach, apple, pineapple, orange)
4. Strawberry jam
5. Orange marmalade
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“Regular “Regular
mango jam” strawberry jam”
“Regular orange
“Regular
marmalade”
pineapple jam”
Shezan also prepares diet jams in 3 different flavors.
1. Diet apple jam

2. Diet mix fruit jam (apple, peach, pineapple, orange)
3. Diet orange marmalade
“Diet orange “Diet apple

marmalade” jam”
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5.12. JAM PREPARATION:-
Jam is prepared by boiling the fruit pulp with sufficient quantity of sugar to a reasonably
thick consistency, firm enough to hold the fruit tissue in position.
In its preparation, about 45 parts of fruit should be used for every 55 parts of sugar. It should
contain not less than 68.55555% soluble solids as determined by the Refractometer when
cold.
The basic procedure of any jam is as follows:
Ingredients:
 Fruit pulp
 Sugar
 Pectin
 Citric acid
 Potassium sorbate
 Color
 Flavor
Procedure:
1. Put the measured amount of pulp in the double jacketed steam cooking pan and start
agitation.
2. Sugar is added in the pan according to the recipe and the steam valves are opened to
cook this mixture at 100°C-105°C and 30 bar pressure for 25 minutes.
3. When boiling starts, sugar and pulp get dissolved, remove the steam application.
4. Now pectin is added by making a solution of pectin and sugar at 70°C-80°C
temperature of the mixture. After the addition of pectin avoid boiling.
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5. Now citric acid, potassium sorbate, and color are added by dissolving in water and
agitate these ingredients without application of steam.
6. Adjust the brix of jam to 68-69°
7. Filling of jam is done in the plastic buckets which are also labeled manually and also
in the 400g glass bottles by filling machine which is also capped manually and labeled
mechanically which shows the name of product, ingredients, and expiry date.
5.13. ONLINE QUALITY CHECK AND THEIR PROCEDURES:-
The acidity and Brix of ketchup are checked when 1 batch is completed.
BRIX:

liquid affects its density so the refractive index of ketchup is also affected in the same
pattern.
The brix of Shezan Mango jam is 65-66oBx according to standard.
ACIDITY:
Requirements:
a. Beaker (250 ml)
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b. Mango jam
c. Water
d. Pipette (10 ml)
Procedure:
ii. Add 2-gram sample of mango jam.
Shezan has different packaging sizes of fruit jams:
1. 15 g portion pack
2. 200 g glass jar
3. 440 g glass jar
4. 1050 g tin can
5. 2 kg of plastic bucket
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5.15. FRUIT SQUASH:-
Squash (sometimes known as cordial in British English, and diluting juice in Scottish
English) is a non-alcoholic concentrated syrup used in beverage making. It is usually fruit-
flavored, made from fruit juice, water, and sugar or a sugar substitute. Modern squashes may
also contain food coloring and additional flavoring.
Shezan prepares fruit squash of five different flavors.
1. Mango squash
2. Orange squash
3. Lemon squash
4. Lemon barley squash
5. Pomegranate (Anar) squash
“Lemon barley
squash” “Mango squash”
“Pomegranate
(anar) squash”
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5.16. PARTS OF SQUASH PRODUCTION LINE:
1. Roller conveyor
2. Rinser machine
3. Blower
4. Conveyor
5. Juice filling tubes
6. Inspection light
7. Capper/ crowner
8. Inspection light
9. Labeling
10. Packaging
ROLLER CONVEYOR:
At this conveyor, the empty PET bottles are placed manually from the start and then the
bottles move further.
RINSER MACHINE:
The rinser machine then picks up the bottle from the roller conveyor and turns their
position. The head of the bottle is below the rinser tube. The empty bottles are washed by
cold or freshwater.
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BLOWER:
After rinsing, the blower transfers the empty bottle with the pressure of air.
JUICE FILLING TUBES:
After blowing the bottle, the bottle moves towards the conveyor that passes the bottle to
the juice filling tubes. 30 bottles fill at a time.
INSPECTION LIGHT:
After juice filled in the bottles, the bottles are again automatically placed on the conveyor
from they pass in front of the screen with florescent light in it. A group of 2 workers
inspects the juice-filled bottles and separate the empty or low filled bottles.
86 | P a g e
CAPPER/ CROWNER:
After passing through the inspection light, the bottles are moves towards the capper. Here
the caps are adjusted on the bottles. Then a screw conveyor tights the bottle caps. 6 caps
are fitted at a time.
While in all the process from juice filling to capping, waterfalls on the bottles to maintain
their temperature.
Labeling:
When the cappers are done on the juice-filled bottles, the bottles automatically placed on
the conveyor, and then labeling is done. Liquid gond (gum) used to stick labels on the
bottles.
87 | P a g e
PACKAGING:
After labeling the bottles are manually packed in a carton. One carton contains 6 bottles.
On the above side of the carton, they manually stamped the batch no, time, date, and
flavor of the squash.
 The bottle size is 800 ml.

 Liquid surf (40-kilo surf + 10 litter water) is used as a foaming agent or lubricant
to reduce the friction of the conveyor components and make the movement of
bottles easy on the conveyer.
Shezan has different packaging sizes of fruit squash.
1. 800 grams PET bottle

2. 1000 ml PET bottle
3. 1500 ml PET bottle
88 | P a g e
CHAPTER# 6
COMPLETION OF
REPORT:-
The four-week time span at Shezan international limited was valuable experience in terms
of knowledge and attaining the techniques of food quality and safety. We found an
opportunity to know the things practically. The above-mentioned activities have honed
our technical expertise and it was a good experience for me.
****************************
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"And it is He who sends down rain from the sky, and We produce thereby

the growth of all things. We produce from it greenery from which We

A report submitted in the fulfillment of

B.Sc. (Hons.) Agricultural Sciences

DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY

This work, the efforts of my

INTERNSHIP SUPERVISORY COMMITTEE

DR. SAJID MEHMOOD NADEEM

Associate Professor (Dpt. SES)

Principal/ Project Director

UAF Sub-Campus Burewala, Vehari

MR. RIAZ AHMED

Shezan International Limited, Lahore

DR. AHSAN KHAN

Assistant Professor (Dpt. PBG)

UAF Sub-Campus Burewala, Vehari

Sr. No. Title Page No.

 Shahnawaz (Pvt.) Limited

 All Shezan products have been certified as 100% Halal.

1.5. QUALITY ASSURANCE:-

2.2. ASEPTIC PACKAGING:

The diagram below illustrates the aseptic packaging process:

The aseptic process flow chart is given below:

Feasibility of Aseptic Machine:

Benefits of using aseptic packaging:

1. It extends the shelf life of products at normal temperatures by packaging them

2.3. PACKAGING MATERIAL:

PACKAGING MATERIAL LAYERS:-

FUNCTIONS AND PERCENTAGE:

 Polyethylene external layer:

2.4. PASTEURIZATION OF JUICE:-

Holding time Cooling time

Shezan produces 3 flavors of juices:

2.5. PLATE HEAT EXCHANGERS:-

Hot water in Product out Hot product in Cool water in

Hot air (125oC)

Squeezing rollers (squeeze or

The above-mentioned equipment should be perfectly cleaned. If H2O2 little concentration

2.7. JUICE FILLING MACHINE:-

2.8. PRINTING PROCESS:-

2.9. STRAW MACHINE:-

2.11. RAPPING MACHINE:-

2.12. SEALS OF TETRA PACK:-

There are three seals manufactured in the tetra pack system:

i. Longitudinal seal (L.S)

2. STRIP APPLICATION SIDE (S.A):

3. TRANSVERSAL SEAL (T.S):

1. TRANSVERSAL SEAL TEST(T.S):

2. STRIP APPLICATION TEST(S.A):-

3. LONGITUDINAL SEAL TEST (L.S):-

Make an oblique cut across the longitudinal seal.

2.14. ONLINE QUALITY CHECKS AND THEIR PROCEDURES:-

CIP CONTROL PANNEL

Method of CIP (cleaning in place):

1- SS- centrifugal pump, capacity> 8000 liters/hour, pressure = 4-5 bar

1. Raw water (For sugar removal)

PUMPS USED IN CIP:-

There are 3 types of pumps used in CIP:

Hot Water Pump