The Coca-Cola Company.: in Plant Training at HCCBPL, Wada

IN PLANT TRAINING at HCCBPL, WADA
The Coca-Cola Company.

Mr. John Styth Perbrton introduced Coca-Cola in1886 and since then it
has grown to become the world no.1 Soft drink. The coca-cola company’s
worldwide headquarter is situated in Atlanta and the Divisional headquarter in
India is Situated at Gurgaon-Haryana.
The Coca-Cola Company is the world’s largest beverage company,
refreshing consumers with nearly 500 sparkling and still brands. Along with Coca-
Cola, recognized as the world’s most valuable brand, the Company’s portfolio
includes 12 other billion dollar brands, including Diet Coke, Fanta, Sprite, Coca-
Cola Zero and vitamin water, POWERADE, Minute Maid and Georgia Coffee.
Globally, we are the No. 1 provider of sparkling beverages, juices and juice drinks
and ready-to-drink teas and coffees. Through the world’s largest beverage
distribution system, consumers in more than 200 countries enjoy the Company’s
beverages at a rate of nearly 1.6 billion servings a day. With an enduring
commitment to building sustainable communities, our Company is focused on
initiatives that protect the environment, conserve resources and enhance the
economic development of the communities where we operate.
About HCCBPL, WADA

CFT, Saralgaon Page 1
HINDUSTAN Coca-Cola Beverages Pvt. Limited, Wada (HCCBPL,

WADA) is a 100% subsidiary of the Coca-Cola Company. This plant has a largest
bottling facility in a country. It is located at scenic and peaceful environment of
village Kudus Taluka Wada, 75 km away from Mumbai in a ‘D’ zone area,
enabling sales tax benefits from state government. Stabling this massive plant in a
rural area of Maharashtra has also opened job opportunities in a rural area of the
state furnishing employment.
The First step in setting up this plant was the procurement of 17.5 acres
land on 15th June’ 1999. Civil construction commenced on 17th June’ just two days
from land acquisition. The plant produced its first commercial batch of product,
Thumps-up within 212 days. On February 02’ 2000 subsequently PET production
started on 25th March and Maaza on 13th April’2000. This Plant is also equipped for
canister filling, the production of which started on 8th May, 2000. HCCBPL,
WADA also equipped with the unique Multi-mix system whereby the beverage for
3 Lines is prepared in the ready syrup room. The main water supply for the plant is
sourced from Vaitarna River which is located
approximately 12 km from the plant. The Maharashtra state electricity Board will
supply electric power to the plant from the substation at Wada, which is 14 km
away. Power is supplied to the plant by an express feeder from the power
substation.

The installed capacity at HCCBPL-WADA
LINE SPEED REQUIREMENTS
Line: 1 (RGB) 600 BPM Bottle washer: 53 pockets/ rows.

Speed: 350 BPR.
LINE: 2 (RGB) 600 BPM Bottle washer: 43 pocket/ raw.

Speed: 350 BPR
Line: 3 (Hot fill RGB) 600 BPM Bottle washer: 53 pocket /raw.
Speed: 350 BPR
Line: 4 (Hot fill PET) 180 BPM Krone contiform Mould: 8 bottle
blowing machine.
Line: 5 (Gold PET) 200 BPM Sidel-10 Mould: 10 bottle blowing
machine.
Line: 6 (High speed PET) 600BPM Sidel – 20 Mould: 20 bottle

Blowing machine
Line: 7 (Packaged drinking water) 60 BPM Sidel Sa Pet,

Mould: 04 bottle blowing.
Line: 8 (Jar line) 400 jars/hr --

Coca-Cola Products.
Coca-Cola:
The Coca-cola is world’s favourite drink in beginning in 1886.It is available

packaging materials like glass bottles, PET container, Can. Glass bottles are available in 200ml & 300ml size.
PET bottles are available in commercial size like 500ml, 1.5 liter, 2 liter, 2.5 liter. Can is available in 330ml
size & fountains are available in various size.
Thumps up:
It is most popular soft drink in India. It has strong Cola taste & made for person
with exiting personality. It has strong, fizzy taste.
Fanta:
It is identified as Fun catalyst. Fanta stands for its vibrant colour, tempting
taste and tingling bubbles that just uplifts feelings but also helps free spirit thus encouraging one to indulge
in the moment.

Sprite:
Worldwide Sprite is ranked as the no. 4th soft drink & sold in more than 190
countries. In India, Sprite was launched in year 1999 & today it has grown to be one fast growing soft drinks,
leading the clear lime categories. Today Sprite is perceived as ‘Youth Icon’. Sprite has stood for a straight
forward and honest attitude. It is available in glass, PET containers, can and fountains of various sizes.
Limca:
“Lime‘n’lemoni Limca” can cast a tangy refreshing spell on anyone, anywhere.

The Limca word is derived from ‘Nimbu’+‘jaisa’ hence “Lime sa”. It is remained unchallenged as the no. 1
sparkling drink in the cloudy lemon segment. The Success formula is sharp fizz and lemoni bite combined
with the single minded proposition of the brand as the provider of ‘Freshness.’
Minute Maid Pulpy Orange (MMPO)
The Florida Food Corporation developed orange juice powder. The Company
developed a process that eliminated 80% of the water in orange juice, forming frozen concentrates that
when reconstituted created orange juice.
MAAZA:

Maaza was launched in 1976. It is a drink that offered the same real taste
of fruit juices and is available throughout the year. Maaza currently dominates the fruit drink category.
Consumers regard Maaza as wholesome, natural, fun drink which delivers the real experience of fruit.
Minute Maid Nimbu Fresh (MMNF):
Recently Coca-Cola launched new fruit drink Minute Maid Nimbu Fresh
which is made from fresh Lemon juice concentrate. Its taste is like a home maid nimbu sharbat. It is made
without addition of any preservatives. Available in PET bottles.
Kinley Soda:
It is one of the best sparkling carbonated soft drink without any added
flavour. It is available in glass bottles and also in PET bottles.
Kinley Water:
It is a packaged drinking water. This water is treated through 5 step process UV treatment, Reverse
osmosis, ozonization, carbon filtration and sand filtration. So it has trust to drink i.e. “Bund Bund Per
Vishvas”
WATER TREATMENT PLANT

Water treatment is heart of any food plant. Water treatment is very crucial in
beverage plant. The Coca Cola Company is very careful about treatment given to
natural water. Water in plant is used for different purpose. Thus raw water is
treated according to the need. Different types of water are termed differently.
A. Raw water
B. Treated water
C. Soft water(chlorinated and un-chlorinated)
D. RO water
E. Backwash recovery
F. Decaustic recovery water
Background
Water is one of the important component of soft drink/fruit juice
processing industries. Water is utilized in the processing plants for generating
steam, washing of bottles, as an heat exchange medium in heating and cooling of
equipment, for cleaning of plant equipment and for protection against fire.
Water obtained for manufacturing is either surface water or ground
water. The Surface water contains high amount of suspended solids and colloidal
organic matter, while ground water contains dissolved solids. The Ground water is
very high in TDS but it has low turbidity.
Water contain suspended solids, it doesn’t carbonate readily. The
Hardness of water further influence on carbonation. Odour found in water alters the
flavor of beverage. Water used for beverage manufacture should not contain
colloidal matter which upon standing may cause precipitation in product.
Source of Water at HCCBPL, WADA

Water available at this plant mainly in the form of three main sources.
 Surface water from Vaitarna river located nearly 12 Km away from the plant.
Analysis of Water

Water is analyzed for following parameters.

1)Colour: The Colour indicates generally the presence of undesirable dissolved,
colloidal and suspended impurities in the water
Examples: Iron turns water to brown/red, Manganese makes it black and
Organics make it yellow.
2)Odour & Taste: It indicates generally the presence of undesirable dissolved

substances, such as hydrogen sulphide or sewage contamination. It important
parameter for water quality control in the food and beverage industry.
3)Suspended Solids: It includes all matter suspended in water that is large enough
to be retained on a filter with a given porosity.
4)Turbidity: It indicates level of colloidal matter of organic or inorganic origin.
The Suspended solids & colloidal matter make water turbid.
5)pH: It is concentration of hydrogen ion mole/l. The pH of pure water is 7, pH
below 7 makes water acidic & above 7 basic.
6)Alkalinity: It can be defined as ability of water to neutralize an acid, which
indicates the quantifiable quantities of bicarbonates, carbonate and hydroxide
in water. It can be determined using Phenolphthalein & screened Methyl
orange indicators.
Phenolphthalein gives the P. alkalinity, P. Alkalinity or P value.
Methyl orange gives the M. Alkalinity, M. alkalinity or M value.
7)Total Hardness: It indicates the quantifiable quantities of calcium and
magnesium. A part of total hardness is associated with alkalinity in water and is
known as alkaline hardness, carbonate hardness or temporary hardness. The

balance of total hardness is associated with non alkaline ions such as chlorides,
sulphates etc. and is known as Non-alkaline hardness or permanent hardness.
8)Total Dissolved Acids: It is defined as total content of dissolved solids in water
which represents all charged ions – Cations, anions as well as uncharged and
molecular species. It is summation of cations i. e calcium, magnesium, sodium
and anions i. e chlorides, sulphates, nitrates and uncharged ions as silica.
9)Electrical Conductivity: It is representative for the purity of water. Higher the
conductivity, higher the content of ions, higher the impurities in water & vice
versa. An empirical relationship exists between conductivity and total dissolved
solids. Electrical conductivity is temperature dependent.
PROCESS FLOW CHART OF TREATED WATER.
Water from Vaitarna River.

Pre filtration plant
Raw water tank.
Co-aggulation tank.
Clear well
Pressure sand filter.
PROCESS WATER TANK.
Deactivated carbon filter (DACF)
Lead-lag activated carbon filter
5 micron filter.
Ultra violet.
.
3 micron filter.
1 micron filter

Syrup room.
Process description
1)Receiving of Water.
Water is received from Vaitarna river with the rate of water drawing is 3380 m3 /
Day. The Water quality is constantly monitored and controlled. The Major part
of water is utilized in beverage manufacturing, which aims to improve water
ratio.
2)Pre-Filtration Plant.
The Prefiltration tank is established to remove granular impurities from the
water. It is important in rainy season, as water received in rainy season contains
high amount of impurities. The Inlet Flow rate is maintained at 90 m3/hr, while
outlet flow rate is 45 m3/hr to each compartment. Pre-Filtration plant consists of
following components.
 Hydro clones: These are used to remove coarse impurities. These are two in
number.
 Clear well: The Water received from hydro clones contains turbidity of
around 12000 NTU. A Continuous dosing of HOCl and FeSO4 is carried
out to flocculate impurities.
 Up flow sand filter: These are two in numbers and used to reduce turbidity
to 10 NTU.
3)Raw Water Tanks

Water purified in Prefiltration tank is stored in raw water storage tanks. Water
treatment plant consists of two raw water storage tank. Each Tank has capacity
of 1000 m3 and tilted design from inner side. The Height of storage tank is 6 feet
and minimum water is maintained at 2.5 feet below. This level is maintained for
emergency use.
4)Coagulation Tanks

Treatment plant consists of three coagulation tanks, among them one is kept on
stand by mode for use in emergency. The Design capacity of coagulation tank is
38 m3/hr. The Incoming flow rate of coagulation tank is 180 m3/hr with
continuous dosing of chemicals. The Dosage includes Lime, FeSO4, and
Bleaching agent of water.
Functions of Chemicals
1)Ferrous Sulphate (FeSO4): It helps in settling of particulate matter. It functions
as a coagulant along with floc formation.
2)Calcium Hydroxide/ Lime: It maintains 2P-M alkalinity.
3)Calcium Hypochlorite: It is bleaching agent and also act as a disinfectant.
Coagulation tank consist of four Zones

1) Mixing Zone.
2) Reaction Zone.
3) Clear Zone.
4) Floc Zone.
5)Clear Well
Clear water from coagulation tank collected in clear well tank, which further
passes water to pressure sand filters though Intermediate pump.
6)Pressure sand filters
The Typical sand filters has cylindrical shape and capacity of 38 m3/hr. The
Sand of different size is used as filtering agent. The Plant consists of three PSF,
having incoming flow rate of 38m3/hr. The Chlorine level is maintained which is
one of the critical control point. The Chlorine acts as disinfectant same time it’s
high concentration affects product quality. The Direction of flow is forward but
in backwash flow direction is reversed. CO2 is injected to the PSF to adjust pH.
7)Process Water Storage Tank

The Water processed in PSF is stored in process water storage tank. It has
capacity to store around 18800 litres of filtered water.
8)Deactivated Carbon Filters.

There are 5 activated carbon filters which has cylindrical shape. It has 2000 mm
diameter and height of 2750 mm. The Filtering aid used is granular activated
carbon along with sand, which adsorbs all impurities and Cl. The Maximum flow
rate of water maintained at 44 m3/hr.
The outlet water do not contains residual chlorine. The Quantity of activated
chlorine used is 2200 kg for each operation. The Backwash flow rate is 190
m3/hr for the duration of 15 minutes.
9)Lead Lag Activated Carbon Filters.

These Filters are added after pesticide issue. These are eight in number and
arranged in alternate manner with four pairs. The Flow rate is maintained at 25
m3/hr. The Granular Carbon is used as filtering aid.
10) 5 Micron filters
These are five in numbers with pore size of 5 micron. The Cartridge type used is
Polyguard 30” Pleated
Polypropylene food grade.
11) Ultra Violet treatment.
The System consists of 16 UV lamps. It aims to reduce microflora by 80 %.
12) 3Micron filters
It has similar construction as that of 5 micron filter with pore size of 3 micron. It
is made up of Cartridge type : Polyguard 30” Pleated Polypropylene food grade.
PROCESS FLOW CHART OF SOFT WATER
Water from Vaitarna River

Pre filtration plant
Raw water Tank
Pressure sand Filter
Softener
No of units: 03
Size: 1200 mm (Diameter), 2500 mm (Height),
Max. Flow rate: 25 m3,
Capacity: 30 M3,
Resin type: strong acid cation, Quantity: 500 liter,
Output between regeneration: 600-800 m3,
Brine tank size: 1000 lit.
Chlorinated Soft water Unchlorinated Soft Water

Cl2 level: 1-3 PPM. capacity: 128000 litre.
APPLICATION:
 CHLORINATED SOFT WATER USED FOR BOTTLE WASHER.
 UNCHLORINATED SOFT WATER USED FOR COOLING TOWER, BOILER.
REVERSE OSMOSIS OF WATER

It was first membrane filtration system used for water treatment. The Process of
reverse osmosis can remove impurities from water down to a molecular weight cut
off of 150 and some organic compound. It also reduces hardness, TDS and
alkalinity of water.
Reverse osmosis is the unit operation in which some solutes in a solution
(from water) are selectively removed through a semi-permeable membrane.
PROCESS:
Reverse osmosis is separation process that uses pressure to force a solvent
through a membrane that retains the solute on one side and allows the pure solvent
to pass to other side. More formally, it is the process of forcing a solvent from a
region of high solute concentration through a membrane to a region of low solute
concentration by applying pressure in excess of the osmotic pressure. This is the
reverse of the normal osmosis process, which is the natural movement of solvent
from an area of low solute concentration , through a membrane, to an area of high
solute concentration when no external pressure is applied. The membranes used for
the reverse osmosis have a dense barrier layer in the polymer matrix where most
separation occurs. In most cases the membrane is designed to allow only water to
pass through this dense layer while preventing the passage of solutes (such as salt
ions). Hence the TDS value of water is reduced after the process. Before entering
into RO membranes water is dosed with Antiscalent agent. Antiscalent is dosed to
avoid scale formation on RO membranes. Scales decrease life of RO membranes
hence need to dose Antiscalent. When water passes through RO membrane clear
water comes at center as reject water remains around it. Clear water is sent to RO
holding tank and a reject water acts as inlet water for 2nd stage RO membranes.
From 2nd stage reject water is sent to backwash recovery while accepted water is
sent to RO holding tank. RO decreases TDS content of water, with this it also
decreases pH of water hence soda ash is dosed to it before going into RO holding
tank. RO water is further used in Jar line and Retail line(Kinley Water). Here
ozonation of water is done which requires water with proper pH as ozonone
dissolution of water changes of pH.
MEMBRANE OF REVERSE OSMOSIS USED AT WADA PLANT

POLYAMIDE
Advantages
1. It can be fabricated into very small pores.
2. It rejects most impurities
3. It also stable from 6 to 10, tolerate fluctuation in temperature
Dis-Advantage
Less than 1 ppm of Chlorine damage membrane. But at this plant, carbon
Purifier using before R.O. unit make Chlorine nil in water.
CAPACITY OF R.O. UNIT GENERATION

1. R.O. water outlet: 15 m3/hr
2. R.O. water rejects: 5 m3/hr
3. Reject water recirculation: 2m3/hr
Back wash Recovery
Water from backwash of PSF.
Setting Tank.
Clear Well.
Pressure sand Filter.
Raw Water Tank.
(1) Taste and odor:

Taste and odor-producing substances such as chlorine, chlorophenols,

chloramines, hydrogen sulfide, and iron can all react with the delicate flavors
in beverages to affect product taste.
(2) Suspended matter:
These particles are undesirable, not only from an aesthetic standpoint, but
they can of carbonation and foaming during filling.
(3) Organic Matter:
Water with appreciable amounts of organic matter may cause neck ring or
floc in the beverage or more after production.
(4) Microorganisms:
Microorganisms are present in most waters. If not removed from the water,
growth may occur several days or weeks after production, resulting in off-
taste and/or off-appearance of the finished beverage.
(5) Alkalinity:
Although alkaline compounds cannot usually be tasted in the water itself,
they can affect the taste of the finished product. Alkalinity may be present in
the water in the form of bicarbonates, carbonates, or Hydroxides.

RMPM (Raw Materials & Packaging Materials)
All Raw materials and Packaging materials required for manufacture final
product; supplied by approved authorized suppliers only. The suppliers should be
approved by Coca cola India by method of audit. These Audits aims to ensure
suitability of raw & packaging materials to product.
Testing of Raw Materials
Every consignment coming for inspection is first checked for
1. Supplier name and location.
2. Date and time of deliver.
3. Quantity delivered.
4. Transportation and vehicle number.
The Materials are categorized into three sections.

 Raw Materials.
 Packaging Materials.
 Auxiliary Materials.
Raw Materials
These Materials are used to prepare final products. The Raw materials includes
concentrates, sugar, Pulp (mango pulp, orange pulp) and CO2.
1) Sugar: Sugar is most important Raw Materials. It is used in most of the
beverage except K.Soda. Various important tests are performed.
a) Taste, odour & appearance.
b) ICUMSA (International commission for uniform method of sugar analysis) this
test is done to check colour of sugar by using instrument Spectrophotometer.
2) CO2 : It is necessary component of CSD beverages. CO2 is necessary to give
fizz effect in the beverage. Following are the tests performed.

1. Odour
2. Purity of CO2:- Specification-99.99%
3. Appearance in water
3) Mango pulp : It is mainly used in hot filled “Maaza” beverage. Mango pulp is
micro-biologically most critical raw material. Hence various physical and chemical
tests are performed for pulp.
1. Appearance (visual).
2. Taste and odour.
3. Brix.
4. Acidity.
4) Orange Pulp: The Orange pulp is used in manufacturing in Minute Maid Pulpy
Orange. The Quality of Orange pulp is analyzed by following tests.
1. Appearance (visual).
2. Taste and odour.
3. Brix.
4. Acidity.
 Determination of titrable acidity of pulp:

Steps:
1) Take the 10g of sample.
2) Add the Phenolphthalein indicator.
3) Titrate with 0.1 N NaOH.
4) Calculate the acidity by using following formula.
Titrable Acidity = ml of NaOH * N of NaOH * Acid Factor
Weight of sample taken

Packaging Materials
These Materials are used for packaging of final product. These Materials
includes Preforms, Closures, Crowns, RGBs, Jars, Labels, sleeves and shrink film.
1) Corrugated Cartons
Tests
 Printing matter/ printing quality.
 Internal Dimension.
 Total GSM.
 Moisture.
 Bursting Strength.
 Delamination.
 Compression strength
 Flute
2) Wrap Around Labels.
Tests
 Printing Quality/ Matter.
 Dimensions (Length & Breadth).
 Total GSM.
 Ink Adhesion.
 Winding.
 Color Shade.
3) PET Preforms
Supplier Name: Amcor PET Packaging,
Future Preforms, Chennai.
Tests
 Weight
 Lack of material on the neck / threads.

 Wall thickness
 Length
 Appearance under polarized light.
 Go-NoGo Guage
4) Closures
Supplier Name: Bericap India Pvt.ltd,
Tests
 Weight.
 Height.
 Printing matter/ Quality.
 Secure Seal Test.
5) Crowns
Supplier Name: Oriental Containers Limited, Murabad,
Tests
 Printing matter/ quality
 Go-No go Gauge
 Weight
 Dimensions
 Liner Quality
 Odour
 Decoration
 Deformed Crowns
 Foreign Crowns
6) Sleeves (MMPO and Maaza)
Tests

 Printing matter/ Quality.

 Colour Shade.
 Ink Adhesion.
 Dimensions.
7) Glass Bottles
Tests
 Height
 Brimful Capacity
 Weight
 Perpendicularity
 Fill Point
 Appearance
8) Jar
Tests
 Weight.
 Height.
 Outer Diameter.
 Drop test.
 Capacity.
 Appearance.
 Neck Diameter.
9) Jar Closures
Supplier Name: Navraj enterprises.
Tests
 Closure Design.
 Weight.
 Colour.
 Leakage test.
 Liner Condition.

 Contamination.
 Light fastness.
Auxiliary Materials
1) Hydrochloric Acid (HCL)
2) Lime
3) Caustic (NaOH)
4) Phosphoric acid
5) Salt
6) Hydrogen Peroxide
7) Calcium hypochlorite
8) Decalite
9) Divo ultra
10) Divo LE
11) Ferrous sulphate
12) Activated Carbon
Effluent Treatment Plant

In Regular industrial operations, a huge quantity of waste water is produced at

manufacturing area. This Waste water is termed as ‘Effluent’. This Effluent has
potentially hazardous nature; hence Government rules and regulations are very
specific before discharging into natural resources. It is Eco-friendly process.
The Maharashtra Pollution Control Board has described the standards for treated
effluent as follows.
There are following parameters to be controlled.

1) COD: It is milligram of oxygen per litre of sample required to oxidised
chemically. It gives the value of total organic matter.
2) BOD: It is milligram of oxygen per litre of sample required to oxidised the
biochemical or biological material present in it.
3) Oil and grease: It is quantity of free or combine oil or grease per lit. of effluent
water.
4) DO (Dissolved Oxygen): It is milligram of oxygen per lit. of effluent legally
present to maintain ecological balance.
5) MLSS (Mix liquor Suspended solids): It shows apparent microbial
concentration in tank. Also includes suspended particles. It can be measured
through
• ½ hour Jar test.
• Gravimetric method.
6) MLVSS (Mix liquor Volatile Suspended solids): It shows actual microbial
concentration in tank. It should be about 80 % of MLSS. It is measured at 600
C in the muffle furnace.
7) F/M ratio: F- food M- micro organism.
It should be equal to or not more than 0.15. It can Control through
recirculation of sludge when M goes down. And Drain sludge in proportion
when the food in the feed decreases (BOD).
8) SVI ( Sludge Volume Index): It is defined as ratio of MLSS by ½ hr settling

method to MLSS by gravimetric method. It should be more than 100, then it is
considered as a Young sludge. Bacteria does not settle fast (in 30 minutes). It
produces white pink foam in aeration tank.
PROCESS
PRIMARY TREATMENT
The main objective of primary treatment is to remove all the large particles like
straws, grit, etc as they would otherwise hamper the further processes. It is
physical process and involves unit operations for better functioning of Biological
and chemical treatments.
1) Effluent Collection
The waste water flow streams captured in effluent collection sump and treated
in the ETP include
- The process Water.
- The Bottle Washer.
- From the WTP.
- Crate Washer.
- From the Syrup Room.
- From the Sugar Solution Preparation room
- Floor Washings
- From Maaza Syrup Room
- From Maaza RGB/ Pet line
- Bar Screen Chamber
A bar screen chamber is the first unit operation in the treatment plant. The
chamber is used for removal of Trash and Debris and prevents big floating
particles to enter the main system. In bar screen chamber where are two bars
provided. A course screen which remove particle size greater than 30 mm and a
fine screen to remove particle size greater than 5 mm. Removal of trash and
debris is essential to prevent blockage of these which further affect the flow of
System.
2) Oil and Crease Trap
Oil and Crease trap is provided to remove floating oil and does not remove
scum and emulsified form of oil. Its removal is essential as presence of oil and
crease would prevent the growth of microorganism in the aeration tank thereby
affecting biological degradation. The floating oil is removed by means of belt oil
skimmer, which is electrically operated. The belt used in the belt oil skimmer is
oleophilic type, where the oil gets attached to the belt and then collected in waste
oil tank. The oil and grease trap has a capacity to remove 3.2 kg/hr.
3)Grit chamber
It is used for removal for sand particles and grits (easily settable solids). Grit
chamber is essential to prevent attrition and wear of pumps and to prevent it from
settling in other tanks. Grit chamber has a other to compartments with 1 tank in
operation at any point of time. The other chamber is stand by chamber. Manual
cleaning of grit chamber is done every 6 months isolating one tank.
4)Collection Sump
The collection sump is where the effluent is collected before being pumped
for main treatment of the effluent. The collection sump has a submersible pump
with a chain pulley block arrangement for removal of pumps for maintenance.
Level switches are provided in a tank. A low level and high level switch
indicates level of effluent in the tank.
SECONDARY TREATMENT
The Secondary treatment includes the degradation of biological matters by
using micro organisms or enzymes.
1)Equalization/ Neutralization
It equalizes the flow and in the process equalizes other parameters like
BOD, COD, TSS, Ph etc.It reduces the ability of system to absorb shock loads
when unusual discharge events occur. Equalization tank is constructed to allow
max 12 hr retention time. The system is designed for fill and draw mode
operation l.e. effluent is stored in one equalization tank for about 12 hrs where it
undergoes ph correction before drawn for further treatment. During drawing of
effluent from one tank the other tank is in filling mode.
2)Activated Sludge Process

Activated sludge process removes suspended and dissolved from waste water
which creates BOD thereby reducing Dissolved Oxygen from which lead to
septic condition and foul smell.

ASP system is based on retention of an adequate biomass. Suspended growth

system is known as Activated Sludge. The System consists of basically Aeration
tank and Clarifier.
Aeration tank
Bacteria grow by consuming food in aeration tank and they are suspended in
clarifier and return to aeration tank for further growth, which termed as Mixed
Liquor Suspended Solids.
MLSS is in the range of 2000-4000 is considered for the design of ASP. Food
to Microorganism ratio (F/M) in the range of 0.1 – 0.3 is considered to design
ASP.
The activated sludge is biologically active and if contains a great no of aerobic
bacteria and other micro organisms which have unusual property of oxidizing
organic matter.
The nutrient required are of nitrogen and phosphorus for the microbial
growth will be fulfilled by the addition of urea solution and Di-ammonium
phosphate. The urea solution shall serve as the Nitrogen and phosphorous source.
The Quantity t both chemicals added would be as to maintain as BOD: N: P ratio
of 100:5:1
The BOD removal is carried out in Aeration tanks. Aeration tank 1 there is
reduction of 60 % BOD and In II there is a reduction of about 40 %.
During Lean season (25%-60%) Aeration tank I is bypassed and the treatment is
carried out in Aeration tank-II.
Aeration is essential to maintain aerobic bacteria are stable operation and to

avoid nuisance conditions like development of Septic and anaerobic condition
which would cause a foul smell.
Diffused Aeration system is used for aerating the tank. Air is passed through
the membranes with opening size approximately 1 mm by means of three 60 HP
blowers.
Diffused air membrane acts like a Non- Return Valve and hence there will be
no choking of the membrane when is air passed through the membrane and there
is settling of sludge in the Aeration Tank.
48 pairs of 1 m are used in each tank and is retrievable type. The waste water
from aeration tank enters in clarifier.
Clarifier:
A secondary clarifier is key element. It is used for sedimentation of readily
settable solids from wastewater effluent. This settling tank have slowly rotating
collector with attached paddles which scrap settled sludge from bottom of tank
and skim floating scum from the surface. Grease removal is also accomplished
during this treatment through removal of scum. Also, it has arrangement for
recirculation of portion of sludge to be mixed with wastewater entering in
aeration tank. It is to be done because returned sludge has viable microorganisms
that actively decompose the waster water being treated.
Overflow of clarifier enters in treated disposable sump. From this, 70% is
transferred to lagoon and 30 % for tertiary treatment.
3) Lagoon
It is generally referred as stabilization ponds which formed artificially in a
plant. Treatment principle involved with lagoons involves biological oxidation
and solid separation. At this plant, lagoon is aerobic type. Aerobic lagoon at this
plant involves use of mechanical agitators to supply atmospheric oxygen for
enhancing biological oxidation. It maintains 1 to 3 ppm of dissolved oxygen in
water. From lagoon, stored water is use for gardening. Hence, this completes the
Water Cycle.
TERTIARY TREATMENTS
The effluent undergoes further treatment so that it can be reused. The water is
sent through a series of chemical treatments, filters to reduce TDS.
Most of water around 70 % is used for gardening and domestic purpose. The
Remaining 30 % of Water is passed to advanced treatment method. The
Advanced method is carried out as follows.
1)Dosing of FeSO4
30 % waste water online mixed with FeSO4 in flash mixer. It acts as a coagulant
and helps in solid separation by its coagulation property from waste water
stream.
2)Clarifloculator
From flash mixer, stream enters in Clarifloculator. It is advanced form of
clarifier. It effectively removes solid particle from water and also removes
coagulated material formed due to mixing of FeSO4
3)Filter feed sump
Clear water stream from Clarifloculator stored in filter feed sump. After this
treatment, clear water passes through Dual media filter. It removes turbidity and
fine particles in water. Whatever fine particles deposited in filter is removed by
backwashing.
Passing of water through U.V. rays
U.V. rays acts as a disinfectant which kills microorganisms in water.
4) Activated carbon filters
It removes fine particle l.e Total dissolved solids, odour and colour from water.
After this water, passes through softener where it get softened. From this, it
passed through 10 u filter.
Start
Collection Sump
Equalization Tank

Biox Tank
Aeration Tank
Clarifier
Treated Sump Tertiary Feed Sump
Lagoon Flash mixer
Gardening Clarifloculator
Filter Feed Sump
End PSF
UF Storage Tank UF ACF
5 micron filter Softener
R. O. Post Tertiary Sump
R. O. Storage Tank Non Process
ACF (Toilet & Floor cleaning)
WTP End

MICROBIOLOGY LABORATORY.
Microbiology laboratory is one of the important section of Quality

Assurance Department. The Microbiological Quality of beverages and water is

analyzed to assure safety of product for human consumption, before dispatch to the
market.
There are following analysis carried out in microbiology laboratory.
Every consignment of raw materials including mango pulp, orange juice and
orange sacks.
Every consignment of packaging materials including glass bottles, jars, preforms,
closures, crowns etc.
Water samples of raw water, treated water, soft water, CIP samples after sanitation.
Coliforms detection is being done in case of Kinley water.
Micro testing of same product in the same week from the same line is not repeated.
Maaza’s every batch is tested.
Two methods for analysis are used which are as follows:
Pour Plate Method: This Method is used for analysis of packaged drinking water
and Maaza syrup.
Membrane Filtration: This Method is used as selective media. The Cellulose filter
paper of pore size 0.45 micron and 0.80 micron are used for analysis of Carbonated
Soft Drinks.
COKE Media:
The Coca-Cola products are analysed by using the media and specifications
provided by TCCQMS. There are following media used for microbial analysis.
1)CC1
The CC 1 media is used for determination of total plate count.
2) CC 2:
The CC 2 media is used for the estimation of yeast & mold count of the
samples.
3) CC 3:
The CC 3 media is used for the enumeration of Coliform in water samples.
4)CC 4
The CC 4 media is used for the determination of faecal coliform count.

5) Orange serum agar:-

For cultivation and enumeration of micro organisms associated with spoilage of
citrus products, cultivation of Lactobacilli and other aciduric organisms and
pathogenic fungi.
B. I. S. Media
The Kinley is Coca-Cola’s brand for packaged drinking water. The Bureau of
Indian Standards has developed standard protocols for testing of packaged
drinking water for Indian manufacturing and storage conditions.
BIS recommended the media which is use for the analysis of package
drinking water. In this include:
 Asparagines Proline Broth.
 Chloramphenicol Yeast Glucose Agar.
 Differential Reinforced Clostridial Broth.
 MacConkey Broth.
 Plate Count Agar.
 Violet Red Bile Agar.
1) Aspergine Proline Broth:-
It is recommended for the cultivation of Pseudomonas aeruginosa using
membrane filter technique.
Principle:-
Aspergine prolein broth is recommended for the cultivation of
Pseudomonas aeruginosa. A.P.B. containing two amino acids which is utilized
by Pseudomonas for their growth. Phosphate & silphate which have ion for
their growth as well as buffer to promote the growth of organisms.
Materials: - media, ethanol, distil water, Autoclave, membrane filter, filter
paper, vacuum flask, laminar air flow.
Organisms Growth
Pseudomonas aeruginosa Luxuriant with greenish
yellow.
2) Chloramphenicol Yeast Glucose Agar
Chloramphenicol Yeast Glucose Agar is a selective medium

recommended for isolation and enumeration of fungi-yeasts and moulds in
milk and milk products, other food stuffs and animal feeds.
Principle and Interpretation:

Chloramphenicol Yeast Glucose Agar is a selective medium recommended
for isolation and enumeration of fungi-yeasts and moulds in milk and milk
products. BIS has recommended this medium for enumeration of yeast and
moulds from food stuffs and animal feeds.
The medium contains yeast extract which provides nitrogenous nutrients and
Vitamin B complex. Dextrose is the energy source. Chloramphenicol- a
thermo stable antibiotic suppresses accompanying bacterial flora. This
improves the shelf life of the prepared medium and can be used over a period
of at least 4 months.
Organisms Growth
Candida albicans good-luxuriant.
Saccharomyces cerevisiae good-luxuriant.
Aspergillus niger good-luxuriant.
Escherichia coli inhibited.
Staphylococcus aereus inhibited.
Differential Reinforced Clostridial Broth:

Differential Reinforced Clostridial Medium is used for the cultivation of
Clostridia from water.
Principle and Interpretation:
Differential Reinforced Clostridial Medium is used for the sulphite reducing
Clostridia from food and for enumeration in water. BIS has recommended this
medium for detection and enumeration of the spores of sulphite reducing
anaerobes, especially Clostridia. Differentiation is based on the ability to reduce
sulphite to sulphide to form iron sulphide resulting in black color. Tryptose, meat
extract, yeast extract, starch, sodium acetate provide essential nutrients for bacterial
metabolism. Glucose is the fermentable carbohydrate. L-Cysteine hydrochloride
acts as reducing agent.

Organisms Growth colour of

colony
Clostridium perfringens good to luxuriant black in
colour
Clostridium sporogenes good to luxuriant
4) MacConkey Media
MacConkey media are differential media recommended for the selection and
recovery of the Enterobacteriaceae and related enteric gram-negative bacilli. This
media is considered as a standard medium for the primary isolations well as
presumptive identification of E-coli.
Principle and Interpretation

Original medium contains protein, Bile salts, sodium chloride and two dyes.
The selective action of this medium is attributing to crystal violet and bile salts,
which are inhibitory to most species of gram- positive bacteria. Gram- negative
bacteria usually grow well on the medium and are differentiated by their ability to
ferment lactose. Lactose fermenting strains grow as a pink and during this produce
acid so bubble form in the Durham tube. The red colour is due to the production of
acid from lactose.
Organisms Growth
Enterobacter aerogenes Luxuriant
Escherichia coli Luxuriant
Salmonella cholerasuis fair to good
Staphylococcus aureus inhibite
5)Plate count agar

Plate count Agar is recommended for the plate count of micro organisms
in foods, water and waste water.
Principle and Interpretation
Casein enymic hydrolysate provides amino acids and other complex nitrogenous
substances. Yeast extracts supplies vit. B complex. Agar is act as a solidifying
agent.
Organisms Growth
Bacillus subtilis luxuriant
Escherichia coli luxuriant
Lactobacillus casein luxuriant
Staphylococcus aureus luxuriant
Enterococcus faecalis luxuriant
Strptococcus pyogenes luxuriant
6) Violet Red Bile Agar:-
Violet Red Bile Agar is selective medium used for the detection and
enumeration of coliform organisms from water and food.
Principle and Interpretation:-
Violet Red Bile Agar is recommended by APHA for the detection and enumeration
of coliform organisms in water, milk, dairy and other food products. It is also
recommended by BIS as a presumptive test solid medium for detection and
estimation of coliform bacteria in food stuff . Druce et al found this medium
equally good as the indicator of coli-aerogenes in milk as MacConkey Broth.
Recently, the agar formulation is recommended by ISO committee for the
enumeration of coliform .

The medium is selective due to the presence of the inhibitors – bile salts and crystal
violet. Crystal violet inhibits gram-positive microorganisms especially
Staphylococci. Organisms which rapidly ferment lactose produce red colonies.
Organisms Growth color of colony

Escherichia coli luxuriant pinkish red w/bile ppt.
Enterobacter aerogenes luxuriant pink
Salmonella enteritidis luxuriant colorless
Staphylococcus aureus inhibited -
SYRUP PREPARATION ROOM.

The Syrup is continuously prepared in syrup room. The Plant is equipped
with two syrup rooms; one for CSD products (Carbonated Soft Drinks) and another
for Fruit beverages (Maaza, Minute Maid). The Syrup is continuously prepared and
transferred to bottling lines. Syrup room is also equipped with CIP system
(Cleaning In Place). The Ready Beverage syrup is prepared in this area which is
finally mixed with Soda water during filling at Bottling line.

There are few terms related to syrup preparation which are as follows:
1) Syrup: It is term which refers to product produced from nutritive sweetener.
2) Preparations: It refers to product produced from nonnutritive sweeteners.
Example: Aspartame in Diet Coke.
3) Brix: The Soluble solids expressed as percent w/w of pure Sucrose in water.
4) Raw Syrup: This Syrup is prepared in equipment called as Contisolve by
mixing sugar, activated carbon and treated water. Raw Syrup is black in colour
due to presence of carbon.
5) Simple Syrup: It is prepared from raw syrup. Raw Syrup is first pasteurized
and filtered continuously to remove various metal ions like Iron, Manganese
etc. Activated Carbon gets binds with metal ions to form bigger mass and
removed by filtration.
6) Final Syrup: It is homogenous mixture of Coca-Cola product concentrates or
beverage base with simple syrup which after adjustment of final volume is used
in production of soft drinks either in bottling plant or fountain customers who
add water to produce finished beverages.
CSD Syrup
The CSD syrup is continuously manufactured in this area and transferred to the
bottling line. It supplies final syrup to both RGB lines and gold PET line. High
speed line has basic difference with these lines that it receives simple syrup. The
preparation of final beverage is carried out at bottling unit itself.
Syrup Manufacturing Process

1)Receiving of Sugar and Activated Carbon.

Sugar is received from sugar hopper and simultaneously activated carbon
is added. Sugar is passed to silo by screw conveyor. It is mixed with activated
carbon and converted into fine granules. Sugar and Activated Carbon is mixed
thoroughly to form uniform mixture .
Then Mixture is passed to Contisolve by using screw conveyor for further
processing.
2)Preparation of Raw Syrup.
Contisolve is equipment which prepares raw sugar syrup from sugar,
activated carbon and hot water. Treated Water is received from Water Treatment
Plant. It is stored in water tank, having capacity of 200-350 Liter. It is heated to
85oc to 90oc & passed to Contisolve. The Heat is applied by using Plate Heat
Exchanger.
Then it is transferred to filters, to remove unwanted particles.
3)D-28 Tank.
The Raw Syrup is stored in holding tank no. D-28. The Purpose of holding
raw syrup is to control filtration process. Filtration is carried out for several times
to remove Iron, Manganese and other impurities along with activated carbon.
4)Micron Filtration.
The Raw Syrup is filtered by using micron filters. It has pore size of 0.45
micron and 38 blades. The Filters are equipped with RJM pump (Radial Jet
Mixing).
5) Pasteurization.
The Pasteurization is carried out by Plate Heat Exchangers. The Plate heat
exchanger has five zones of heat processing. These Zones are as follows:
 Pre-Heating Zone.
 Heating Zone.
 Holding Zone.
 Cooling Zone.
 Chilling Zone.
Preheating is carried out to prepare product for further heat process, also
to avoid thermal shocks. The Heating zone increases the temperature of syrup
and holding section maintains temperature for desired time. It is hold into the
tank D-30. It is again passed through preheating zone; to lower temperature.
6) Simple Syrup Holding.
The Syrup is first analyzed for Carbon carry over by using micron filter
test. The Presence of Carbon residues indicates failure of filtration. Then, this
syrup is again passed to D 009 tank & again filtered. The Absence of Carbon
particles on filter assures efficiency of filtration process.
This Syrup is stored in tank no. 13. This Syrup is referred as Simple
Syrup.
7) Final Syrup preparation
As per required flavour & batch size concentrates & beverage base in cold
store are brought to ambient temp conditions for there addition.
I. Volume of simple syrup taken as per flavor sugar requirement no. of unit
& simple syrup brix.
II. Addition of concentrate in a tank through concentrate trolley.
III. Make up with water as per MMI.
IV. Ready syrup brix & final volume check.
This procedure is followed for each flavor preparation in any ready syrup
tank. Through main distribution panel this ready syrup form transfer in ready
syrup buffer tank, where final beverage is prepared by mixing ready syrup with
treated water which is previously passed through 1 micron filter & de-aeration
tank.Beverage formed from buffer tank enters in beverage holding tank where
intermittent mixing is carried out. From beverage holding tank this syrup
provided according to requirement to particular line.
Maaza Syrup

The Maaza syrup is manufactured in batch process. Each Batch consists of 5

units of simple syrup. The beverages manufactured in this area are Maaza
Mumbai, Maaza regular and Minute maid pulpy orange.
1)Raw Syrup Preparation.

The Raw syrup is prepared by mixing 9000 kg of sugar and 4500 litre of
treated water. The Brix is maintained at 60oc by continuous circulating through
circulation pump. The Activated Carbon is added in syrup tank.
2)Filter Press.
The Raw syrup is prepared & filtered by using micron filter. The Filter aids
are used to improve the efficiency of filters. The Filter is first precoated with
hyflow supercel and celite . It forms thick layer on filter paper. The filter should
be operated at pressure of below 2 psi.
The Filter is turned from white to light pink. The Hyflow binds with
activated carbon and forms bigger particles of particle size of less than 40
micron.
3)Cooling of Simple Syrup.
The Syrup is cooled to 10oc and hold at syrup holding tank. The Tank no. 1 is
used as holding tank. Then, Simple syrup is blended with Mango pulp and
concentrate in tank no. 2 and 3 with addition of sufficient amount of water.
4) Blending
The syrup is blended properly for uniform mixing of pulp, syrup and concentrate.
The various concentrates are used and added in particular sequence. The
sequence of addition of syrup is as follows.
5)Homogenization.
Homogenization is defined as the unit operation carried out which reduces the
particle size of product by applying high pressure. Maaza contains mango pulp &
pulp contains fibre, so homogenization is done because of increased efficiency of
filling process.
The Homogenization of blended syrup is carried out by two stage
Homogenizer. The Homogenizer works at two stages which are as follows:

 1st Stage: 500 psi.

 2nd Stage: 2600 psi.
The Homogenizer consists of fine blades which reduces the particle size of
fibres, gives homogenous mass of syrup which is referred as Ready Beverage. It
is stored in tank no. 4 and 5. With brix is maintained at 15.56o. This Ready
beverage is transferred to bottling line for filling.
6)Volume make up.

The Water is added to balance the sugar content within the beverage.
The Quantity of water to be added to balance the sugar content is determined by
following formula.
Brix – Required brix * Volume of final volume = Required water for final
addition.
Required brix
BOTTLEING UNITS.
RETURNABLE GLASS BOTTLES
Carbonated Soft Drink.

FLOWCHART:
Loading cases on conveyor belt.
Decaser.
Pre Wash Inspection.

Bottle Washer.
Ready Beverage Post Wash Inspection.
Carbonator Filler.
Post fills inspection.
Caser.
Palletizer.
Production Warehouse.
Principle: - Isobaric pressure filling.

Beverage gets filled in a bottle through the side wall due to scut present in
valve. During filling as beverage get filled in a bottle get replace back to filler tank.
When vent tube get filled with beverage co2 can’t escape through vent tube. The
head space co2 removed by sniff valve action.
Line Description
RGB Line no. 1
1. The Line has operating speed of 600 BPM and works on the principle of
counter pressure filling.
2. The Bottle washer has two soaks, among them second soak is important.
Washer has five rinses and Cl2 content of final rinse is 1-3 ppm.
3. The Line has special feature i. e. EBI system (Empty Bottle Inspection). It is
integrated system consists of monitoring every bottle for no. of defects.
4. The Line has one CCP. i. e. glass particles of broken bottles at the filler.
5. The Parameters (Cp/Cpk) under constant observation are as follows.
 Brix. (Except Kinley Soda).
 Carbonation of beverage.
RGB Line no. 2
1. The Line has operating speed of 600 BPM and works on the principle of
counter pressure filling.
2. The Bottle washer has three soaks, among them second soak is important.
Washer has five rinse and Cl2 content of final rinse is 1-3 ppm.
3. The Line has one CCP. i. e. glass particles of broken bottles at the filler.
4. The Parameters (Cp/Cpk) under constant observation are as follows.
 Brix. (Except Kinley Soda).
 Carbonation of beverage.
Maaza
FLOW CHART
Loading cases of empties on conveyor.
Empty cases Case washing. Uncaser.
Pre Wash Inspection.

Bottle Washer
Post Wash Inspection Maaza Beverage.
Pre Heating of Washed Bottles. Pasteurizer.
Hot Filling of Pasteurized Beverage. Magnetic Trap & Strainer.
Crown hopper Crowning
Cooling Tunnel
Date Coding
Filled Bottle Inspection
Caser
Palletizing.
BSR Go down.
Product Release & Dispatch.
Principle: Gravimetric Filling.

The Bottle is filled with beverage under the action of gravity force. The
beverage is filled at high temperature so that it creates vacuum inside the bottle
after crowning. The Vacuum produced within the bottle prevents the growth of
microorganisms.
Line Description
1) Filler is operated at the speed of 320 BPM and bottle washer at the speed of
350 BPM.
2) Bottle washer consists of three soaks and five rinses. The Second soak is
considered as ‘Main soak’.
3) The Pasteurizer used for operation, consists of Plate Heat Exchanger. The
Pasteurization temperature is monitored at every 2 minutes frequency and recorded
in data logger. Also manual monitoring is carried out after every 2 hours.
4) Cooling tunnel consists of four temperature zones. It is monitored at every 2
hours frequency.
5) The Line consists of two CCP. The First CCP is pasteurization temperature
and another is glass particles at bottle filler.
Maaza Quality Parameters

Parameters
1. Taste
2. Odour
3. Appearance
4. Titrable acidity
5. Micron size
6. Viscosity
7. pH
8. 0 Brix
9. Pasteurization
temperature
10. Vacuum
11. Date code
12. Foreign
particles
13. Package
attributes
14. Beverage
temperature at
cooling tunnel exit.
15. Colour.
Bottle Washer
The Bottle washer is machine which is capable of cleaning and sanitizing huge
quantity of bottles within short period of time. The Washer is designed and
constructed by Sidel company.
The washer consists of mainly four sections. The First section is prewash, then
soak and followed by rinse section.
1) Prewash Section
In this section, Bottles are wetted with water to improve action of caustic. It
consists of two jets with minimum pressure of 1bar.
2)Soak Section
The Soap additives like Divo Ultra are used to improve efficiency of soap. The
Soak section is again subdivided to control temperature of washer.
 Soak 1
This Soak functions as a warmer. The Temperature is maintained to avoid

breakage of glass bottles at high temperature.
 Soak 2 / Main Soak
This Soak has important role in bottle washing process . The Efficiency of
soup is found to be maximum at this temperature. All dirt is removed along
with date code.
 Soak 3
This Soak do not have significant role in bottle washing. It improves
washing efficiency.
3) Hydro wash section

The Overflow water from soak and rinse section gets collected into the hydro
section. This Compartment has no specific function. It is used for moistening of
bottles.
4) Rinse section
The Rinse section removes traces of soak solution by using soft water. It is
again subdivided into five compartments.
 Pre-rinse 1, 2 & 3
These Sections removes soak solution by using treated water which is
followed by prefinal rinse.
 Prefinal rinse
The Continuous dosing of soup additives like Divo AI & Divo LE is
carried out. Divo LE reduces hardness of water, which can seriously impact
on product quality. Divo AI functions as pH regulator. The pH is monitored
by digital pH indicator. Caustic solution in soak section elevates pH, which
is controlled by Divo AI.
 Final Rinse
The Chlorinated soft water is used in final rinse section.
Controlling Parameters
The Efficiency of Bottle washing operations is maintained by control at various

points. These are described as follows.
1)Caustic concentration:
The Caustic consumption is monitored regularly at every 4 hours. The Caustic
consumption has direct effect on washing efficiency.
Procedure
• Take 10 ml of the detergent solution in a clean flask.
• Add 2-3 drops of Phenolphthalein indicator to the sample.
• Titrate the sample against the H2SO4 with continuous agitation till the pink
colour just disappears. Record the burette reading as ‘P value’.
• Add Methyl purple indicator to the sample solution. The Solution becomes
green in colour.
• Titrate against H2SO4 till green colour gets converted into grayish purple.
• Record the total burette reading as ‘M value’.
Calculation
Caustic concentration= (2P - M) * 0.4.
2)Additive concentration (Divo ultra)

The Additive Divo ultra is used along with caustic to improve washing
efficiency. The Previous Date coding is erased by using Divo ultra. The
Concentration of additive is analyzed by using procedure specified by Johnson
Diverse Company
3)Total Hardness
The Total hardness of rinse water should be maintained at below 100 ppm. It
is measured by following procedure.
Procedure
• Take 100 ml of sample and add 2-3 drops of Ammonia buffer.
• Crush and add total hardness tablet.
• Swirl for some time till the tablet dissolves.

• Titrate with EDTA solution and record titration reading.
Calculation
Total Hardness in ppm= Reading ml * 10.
4)Free Chlorine
The Chlorine content of rinse solution is measured by following procedure.
Procedure
• Take 10 ml of sample in 10 ml cell and add 1 DPD no. 1 tablet.
• Swirl for some time, till tablet gets dissolved.
• Put cell in Lovibond computer and compare colour of cell with disc cell.
• Note reading in ppm.
5)Divo LE test
Divo Al is used to control the hardness of water.
Procedure
• Take 100 ml of sample.
• Add 2-3 drops of Ammonia buffer.
• Add Erichrome black indicator.
• Titrate against Divo LE reagent.
Calculation
Divo LE= Titre value * 0.95.

Carbonated Soft Drinks.

GOLD PET LINE.
Flowchart
Preforms Hopper.
Preforms Feeding Conveyor to Sidel.
SIDEL
(Preforms are Blown & Molded to form bottles).
Blown Bottle carrying Air Conveyor.
Labeler (labels are applied on bottles). Ready Beverage from Syrup room.
Bottle Rinsing with Soft Water Cl2 1-3 ppm. Carbonation .

Filling.
Capping.
Date Coding.
Warmer.
Caser.
Carton Date Coding.
Carton Top Sealer.
Palletizer.
BSR Go down.
Filling Principle: Counter pressure filling.

Beverage gets filled in a bottle through the side wall due to scut present in
valve. During filling as beverage get filled in a bottle get replace back to filler tank.
When vent tube get filled with beverage CO2 can’t escape through vent tube. The
head space co2 removed by sniff valve action.
Steps in filling
1. Pre-evacuation: The Vacuum is produced by removing air within the bottle
by vacuum pump.
2. O2 Filling: O2 is filled within the bottle by using vent tube.

3. Beverage filling: When the pressure inside the bottle gets equal to outside
pressure beverage is filled along the side wall of bottle.
Line details
1) Gold PET line is used for filling of PET bottles with operating speed of 200
BPM.
2) The Preforms are blown and moulded to form bottles by using SIDEL
machine. It has 10 moulds.
3) A High carbonation is given as compare to RGB units, to counter balance the
loss due various factors.
4) The Pack size of 350ml, 500 ml, 600 ml, 1 litre and 2 litre are filled.
HIGH SPEED PET LINE.

Flowchart
Preforms Hopper.
Performs Feeding Conveyor to Sidel. Simple syrup.
SIDEL
(Preforms are Blown & Molded to form bottles). Ready syrup.
Blown Bottle carrying Air Conveyor. Beverage.
Bottle Rinsing with

Soft Water Cl2 1-3 ppm. Carbonation.
Filling.

Capping.
Fill Level detector.
Laser Date Coding.
Warmer.
Bottle Dryer Chamber.
Labeler (labels are applied on bottles).
Shrink Wrapping
Declaration Label Applicator
Palletizer.
Pallet Stretch Wrapping
BSR Go down.
Principle: Volumetric filling principle.

The filling is done by volumetric filling phenomenon. The CO2 is first injected
followed by beverage. The Maximum quantity of CO2 gats dissolved in the
beverage and remaining gas gets collected in the head space.
Line details
1) The Specialty of these unit is with its high speed. The Bottling unit has speed
of 1200 BPM for pack size of 500ML.
2) High speed filler works in absence of vent tube. Also it has 108 filling nozzle
and 18 capping heads.
3) Line have unique feature that beverage is prepared at the bottling area.
4) The Moulding machine have 20 molds.
5) Labeling is done after filing while at Gold PET line, it is carried out before
filling.
HOTFILL PET MAAZA

Flowchart
Preforms Hopper. Ready Beverage.
Preforms Feeding Conveyor to Sidel.
Krones. Balance Tank.

(Preforms are Blown & Molded to form bottles)
Blown Bottle carrying Air Conveyor. Pasteurization & Trim cooling.
Bottle Rinsing with Soft Water Cl2 1-3 ppm.
Closure Hopper Filling. Magnetic Trap & Strainers.

Closure Treatment Neck rinsing &Capping.
Tilting conveyor.
Cooling Tunnel (Temp < 40°C).
Sleeving.
Date coding.
Inspection Station.
Case Packing.
Carton coding.
Palletizing.
BSR Go down.
Principle: Gravimetric Filling.

The Bottle is filled with beverage under the action of gravity force. The
beverage is filled at high temperature so that it creates vacuum inside the bottle
after crowning. The Vacuum produced within the bottle prevents the growth of
microorganisms.
Line Description
1) The Product manufactured are hot fill PET Maaza and Minute maid pulpy
orange with operating speed of 180 BPM.
2) Krone moulding machine with 8 moulds is used.

3) Tubular heat exchanger is used for pasteurization and other heat treatments.
Packaged Drinking Water.

JAR LINE
Flow chart
Receiving of Empty Jars. RO Water from WTP
Inspection for heavy dust or dirt. 1 µ Filter
Prewash. 0.22 µ Filter
Washed jar inspection.
Jar washer Ozonated Product Water

Holding Tank
Washed Jars
Filling Process
Capping Caps Rinsing with Ozonated Water.
Date Coding
Filled Jar Inspection
Plugging & Hologram Application.
Finished Product
Microbial Checks as Per BIS
Stock Transfer
Process details
1)Jars of 20 litre capacity are filled with Kinley water with operating speed of 400
jars per hour.
2)Jars are made up of either PET (Polyethylene Terphthalate) or PC containers.
3)Poly brite is used as cleaning agent for jars.
4)Jar washing is carried out in two sections; one is prewash which is followed by
main washer. Pre wash is used for rinsing and surface washing of jars. Main
washer has major function in washing process.
Jar washer has four compartments.

1.Pre-rinse: The Jars are rinsed with chlorinated soft water. It is carried for
moistening purpose.
2.Washing: washing is carried out with the help of detergent namely Poly brite.
It gives glossy appearance to jars.
3.Pre-Final rinse: it is carried out by using R. O. water which do not contains
ozone.
4.Final rinse: Here Ozonated R. O. water is used with concentration of ozone is
1 ppm.
5)The Minerals formulation is being trade secret of company. It includes NaCl and
MgSO4.
6)The R. O. water received from water treatment plant is filtered by using two
micron filters, first is 1 micron filter and another is 0.22 micron filter.
7)Ozone is added in the product which functions as disinfecting agent.
8)Ozone gets disintegrated to oxygen after 24 hours hence stock of final product is
stored for 48 hours.
The Ozone level should be at zero before dispatch of product to the market.
Kinley Water Retail Line

Preform Hopper. RO Permeate Water from WTP
Preform Feeding Conveyor to Sapet Passing through UV Treatment
SAPET
(Preforms are Blown & Moulded to form bottles) Mineral Injection System
Blown Bottle carrying Air Conveyor. Passing through 1micron Filter

Bottle Rinsing with Ozonated Water min 0.2 ppm passing through 0.22micron Filter
Filling
Cap Hopper Capping
Date Coding
A. Label Rolls Labeler

(labels are applied on
bottles except Schweppes)
B. Shrink Sleeves Shrink Tunnel

(Warmer for Schweppes)
Filled Bottle Inspection Carton Forming
Manual Casing Formed Cartons Conveyor
Manual Carton Top Sealer
Palletizing
BSR Go down
Product Release & Dispatch

Process details
1)The Preforms used for blowing of bottle is made up of PET.
2)The Preforms are blown and molded into bottles by using SAPET molding
machine. The Machine consists of 4 molds.
3)Blown bottles are rinsed with Ozonated water.
4)The Filler consists of 24 nozzles; hence first 24 bottles of each batch are
removed. The Chances of contamination in first 24 bottles are higher than next
bottles.
5)The Pack size of 300 ml and 1 litre is manufactured with operating speed of 60
BPM.
6) The Minerals formulation is being trade secret of company. It includes NaCl
and MgSO4.
1)The R. O. water received from water treatment plant is filtered by using two
micron filters, first is 1 micron filter and another is 0.22 micron filter.
2)Ozone gets disintegrated to oxygen after 24 hours hence stock of final product is
stored for 48 hours.
The Ozone level should be at zero before dispatch of product to the market.
CIP (Cleaning In Place)

The HCCBPL, Wada has completely automated flexible system of CIP is
working. The Machineries has direct contact with final product. Cleaning of
machines at outside place is not practical in regular operation. Hence, cleaning is
carried out at the manufacturing area itself. Various types of CIP are carried out to
assure the safety of product within feasible cost. It is installed in syrup room and
Maaza syrup room.
The CIP is carried out for following reasons
 Product / Flavour change over.

 Scheduled CIP.
 Batch change.
The CIP system within plant consists of following components.
1. Fresh water tank.

It supply and recirculate hot water to tank or line which is connected to CIP
Circuit.
2. Recuperation tank.
It recovers water from final rinse and gives water for pre-rinse.
3. Hot Lye tank.

It recovers water from final rinse and gives water for pre-rinse.
4. Caustic tank.
It is used to hold the caustic solution for IP.
5. PHE (Plate Heat Exchanger)
It increases temperature of caustic solution and hot water.
Functional areas
The CIP is given to following areas
1. Syrup holding tank.
2. Syrup making machineries.
3. Filler and equipments at bottling unit.
4. R. O. Water holding tank located at WTP.
Types of CIP.
There are following types of CIP carried out in the plant.
1. Flushing CIP.
CO2 is flushed to remove trace of water so that during startup there is no
problem of final rinse water in product.
2. 2 Steps CIP.
It is generally done when we already done CIP but equipment is not used for
several hours or a day. It ensures no interference of microbes in products.

It involves following steps

1) Hot water Rinse
2) Treated Water Rinse
3. 5 Steps CIP.
1)Pre- rinse
It occurs from water recovery previously used water from final rinse in
previous CIP, Stored in Recuperative Tank. After its application it gets
drained. It is carried out for 5 minutes.
2)Caustic Rinse
It occurs (Recirculation) via caustic tank. During Caustic rinse temperature
of water is maintained. It loosens and removes residual flavour and
remnants from equipment surface. Caustic rinse water is recovered. The
Caustic rinse is carried out for 15 minutes.
3) Intermediate Rinse/ Water rinse.
Again intermediate rinse is given to prevent the deposition of the remnant
upon the clean surface and remove any residual detergent. This water is
recovered in hot caustic tank as it contains residual NaOH. Currently, It is
not in practice.
4) Hot water Recirculation
Temperature of hot water maintained by PHE. In PHE, temperature of
water gets maintained. It destroys microorganisms and eliminates
contamination. It is recovered in tank. It is also not carry out.
5) Final Rinse
Treated water is used mainly for final rinse. It cools equipment and also
removes all traces of sanitizing agent. It is carried out for 15 minutes. For
optimal efficiency and to reduce effluent discharge, It is recovered in
recuperative tank.
4. 6 Steps CIP.
It involves additional step of Acid recirculation / rinse. Acid commonly
used is phosphoric acid. It removes acid soluble impurities.

It generally done in plant once a week.

It involves following Steps
1)Pre-rinse.
The Basic purpose of pre rinse is similar to pre rinse in 5 step CIP. It is
carried out for 10 minutes.
2)Caustic rinse.
It is carried out to remove flavour and remnant within the tank. It is carried
out for 15 minutes.
3) Intermediate Rinse.
4) Acid Rinse.
The Purpose of acid rinse is to remove scal formed at inside area of pipe.
The Scald has large number of micro pores, microorganisms can hide
within these pores. Caustic is not capable to kill the microorganisms. It is
carried out for 20 minutes.
5) Hot Water Sanitation.
6) Final Rinse.
Analysis of Market Samples
The Storage environmental conditions show high degree of variation in
market. It has direct effect on product quality in terms of carbonation and brix
value. The Carbonation loss is a result of environmental temperature. The Change
in brix value occurs due to phenomenon of inversion.
Reassurance of market samples.
 Consumer Awareness.
 To get feed back from consumer regarding the quality of beverage.
 It also check to see whether the Co2 standards and brix ( inversion of sucrose)
which are maintain during processing are retain the beverage till it reaches to
the consumer.
Procedure
1. The Gas volume of market sample is measured by using Carbonation
tester.
2. The Sample is degassed by using vacuum pump.
3. The Sugar content is analyzed by using inversion test.
4. All quality parameters are analysed

5. The Value of BPQI and PCQI are determined by using following
formulae.
BPQI = Beverage Product Quality Index

BPQI = Appearance*Taste*Gas volume*Brix*100
Total no. of sample

PCQI= Primary container Quality Index
PCQI= Container condition* Closure condition* Closure

function*Date code* Net content * 100
Total number of sample
Inversion Test
Preparation of Inversion acid solution.
It is prepared by adding 98% pure HCl into 720 ml distilled water. The Density of
Inversion acid is found to be 1.0408 gm/cm3.
Procedure
Take 50 ml of sample.
Add 0.3 ml of Inversion acid and place it in water bath at the temperature of 700c
for 20 min.
Cool to ambient temperature.
Load the sample in DMA and record the reading.
Calculation
Brix value= Inverted Brix * 0.95.

Important Terms
1. PH- Negative logarithm of H+ ions concentration.
2. Acidity- Presence of H+ ions (0-6)
3. Base- Presence of OH- ions (8-14)
4. Quality- The ability of product to satisfy the customer needs with maintaining
the degree of excellence.
5. Viscosity- To resistant the rate of flow. (Unit-centipoises)
6. Normality- Amount of molecule to neutralize solution.
7. Activated carbon- Adsorptic particle or granules of carbon usually obtained

by heating carbon.

8. Alkalinity- The capacity of water to neutralize acid.
9. Hard water- Presence of calcium, magnesium, like minerals in water called

hard water.
10. Soft water- Water having a low concentration of calcium and

magnesium ions.
11. Oxidation- It is the removal of electron from organic matter.
12. Turbidity- A measure of the amount of suspended colloidal particulate

matter in water unit NTU(Nephlometric Turbidity Unit)
13. Brix- The percentage of total dissolved solids by weight in case of

beverage is considered as the percentage of sugar by weight.
14. Carbonator- A device that converts simple water to carbonated water

under pressure.
15. DO (Dissolved oxygen) - Molecular or free oxygen dissolved in water

or waste water.
16. Homogenizer- The process of blending the fibrous particle.
17. Gas volume- It is defined as the volume of CO2 gas dissolved by one
volume of water at atmospheric pressure.

18. Reverse osmosis- It is the process of forcing the solvent from a region
of high solute concentration through a membrane to a region of low solute
concentration by applying pressure.
19. Indicator- A substance that gives a visible color change at a desired

point in a chemical reaction generally at a end point of a titration.
20. Morality- Morality is the no. of moles of a solute dissolved in a liter of

solution.


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The Coca-Cola Company.: in Plant Training at HCCBPL, Wada

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IN PLANT TRAINING at HCCBPL, WADA

The Coca-Cola Company.

About HCCBPL, WADA

HINDUSTAN Coca-Cola Beverages Pvt. Limited, Wada (HCCBPL,

CFT, Saralgaon Page 2

The installed capacity at HCCBPL-WADA

LINE SPEED REQUIREMENTS

Line: 1 (RGB) 600 BPM Bottle washer: 53 pockets/ rows.

LINE: 2 (RGB) 600 BPM Bottle washer: 43 pocket/ raw.

Line: 6 (High speed PET) 600BPM Sidel – 20 Mould: 20 bottle

Line: 7 (Packaged drinking water) 60 BPM Sidel Sa Pet,

Line: 8 (Jar line) 400 jars/hr --

CFT, Saralgaon Page 3

The Coca-cola is world’s favourite drink in beginning in 1886.It is available

CFT, Saralgaon Page 4

“Lime‘n’lemoni Limca” can cast a tangy refreshing spell on anyone, anywhere.

Minute Maid Pulpy Orange (MMPO)

CFT, Saralgaon Page 5

CFT, Saralgaon Page 6

Source of Water at HCCBPL, WADA

CFT, Saralgaon Page 7

Water is analyzed for following parameters.

2)Odour & Taste: It indicates generally the presence of undesirable dissolved

known as alkaline hardness, carbonate hardness or temporary hardness. The

PROCESS FLOW CHART OF TREATED WATER.

Water from Vaitarna River.

CFT, Saralgaon Page 9

Pre filtration plant

Raw water tank.

Pressure sand filter.

PROCESS WATER TANK.

Deactivated carbon filter (DACF)

Lead-lag activated carbon filter

CFT, Saralgaon Page 10

3)Raw Water Tanks

CFT, Saralgaon Page 11

Coagulation tank consist of four Zones

7)Process Water Storage Tank

8)Deactivated Carbon Filters.

9)Lead Lag Activated Carbon Filters.

PROCESS FLOW CHART OF SOFT WATER

Water from Vaitarna River

CFT, Saralgaon Page 13

Pre filtration plant

Raw water Tank

Pressure sand Filter

Chlorinated Soft water Unchlorinated Soft Water

REVERSE OSMOSIS OF WATER

CFT, Saralgaon Page 14

MEMBRANE OF REVERSE OSMOSIS USED AT WADA PLANT

CAPACITY OF R.O. UNIT GENERATION

Back wash Recovery

Water from backwash of PSF.

Pressure sand Filter.

Raw Water Tank.

(1) Taste and odor:

Taste and odor-producing substances such as chlorine, chlorophenols,

CFT, Saralgaon Page 17

RMPM (Raw Materials & Packaging Materials)

The Materials are categorized into three sections.

CFT, Saralgaon Page 18

 Determination of titrable acidity of pulp: