A PROJECT REPORT ON BISLERI PACKAGED DRINKING WATER

PVT. LTD.

A project report submitted to St. Aloysius College (Autonomous) for the

partial fulfillment of the requirement of degree in

BACHELOR OF VOCATION IN FOOD PROCESSING AND

ENGINEERING

By

MOIDEEN AFREED H
REG NO:190113

Bachelor of Vocation in Food Processing and Engineering

St. Aloysius College (Autonomous)
Mangalore-575 003
 Bachelor of Vocation in Food Processing and Engineering

ST. ALOYSIUS COLLEGE (AUTONOMOUS)

MANGALURU-575003

CERTIFICATE
This is to certify that MOIDEEN AFREED H (190113) of sixth semester B.Voc Food
Processing and Engineering has undertaken the project entitled A PROJECT
REPORT ON BISLERI PACKAGED DRINKING WATER PVT. LTD. towards the
partial fulfilment of the requirement of Bachelor of Vocation in Food Processing
and Engineering by St. Aloysius College (Autonomous), Mangaluru. No part of
this thesis has been presented for the award of any other degree

Dr. Adarsha Gowda Dr. Denish

HOD (guide) Director

The external examiner

 ACKNOWLEDGEMENT

First, we express our thanks to god almighty in guiding and blessing us

for making this project a great success. we are heartily thankful to each
and every one for the guidance and support for completing our great
effort.

We express our profound to the Bangalore bisleri industry HR Manager

for granting us the permission for the project in company. We also owe
thanks to, Mr. SIDDESH (Quality Executive) and each and every
department staffs for their guidance and whole-hearted co-operation
during the period of training.

It is our privilege to extend our sincere thanks to, Mr. Jadav (Quality
manger) and Miss. Kurath (laboratory assistant) and Miss.Chandrani
(laboratory assistant) for their co- operation and guidance.

We convey our sincere gratitude to our respected teachers DR.

ADHRASHA GOWDA (Head of the Department), MISS. JENISSA CINORA
(class guide) MRS. CLARET (class guide) MR. NEVIL (staff)
MRS.SANGEETHA (staff) in Department of Food processing and
engineering for allowing us to undergo the training and for the valuable
guidance.

Finally, we thank our parents and friends, who sparked the spirit of
enthusiasm and sculptured us in to the present position. They were
always supporting and encouraging us with our welfare in mind
 ABSTRACT

Water is perhaps the most precious natural resource after air. Though the surface
of the earth is mostly consisting of water, only a small part of it is usable, which
makes this resource very limited. This precious and limited resource, therefore,
must be used with prudence. As water is required for different purposes, the
suitability of it must be checked before use. Also, sources of water must be
monitored regularly to determine whether they are in sound health or not. Poor
condition of water bodies is not only the indictor of environmental degradation, it
is also a threat to the ecosystem. In industries, improper quality of water may
cause hazards and severe economic loss. Thus, the quality of water is very
important in both environmental and economic aspects. Thus, water quality
analysis is essential for using it in any purpose. After years of research, water
quality analysis is now consisting of some standard protocols. There are guidelines
for sampling, preservation and analysis of the samples. Here the standard chain of
action is discussed briefly so that it may be useful to the analysts and researchers .
 COMPANY PROFILE

In 1967, Bisleri an Italian company, started by Singer Felicebisleri, fi rst

brought the idea of selling bottled water in India. It started a company called
Bisleri India. In 1969, Ramesh Chauhan, the Chairman of Parle Exports, bought
over the brand. In those days, Bisleri packaged drinking water was available in
glass bottles. Being a returnable package owing to various other problems such as
breakage and w e i g h t , i n 1 9 7 2 - 7 3 , B i s l e r i w a s m ad e a v a i l a b l e in P V C
(Poly Vinyl
C h l o r i d e )  bottles. After this plastic packaging was introduced, things started to c
hange, andsales increased rapidly. The upsurge in the sales of Bisleri started in
1993 as Ramesh Chauhan sold off the Parle stable of brands, including Thums
up, Limca and Gold Spot. Recognizing
the potential of the drinking water market, he then went on to concern trade on
marketing Bisleri a top selling brand in India.

THE PRESENT

It was around the year 1995, when Parle Export took charge of the brand
operations and the business took off in the market. With factories across India
and a strong distribution network, Bisleri established itself a force a reckon with in
the domestic packaged drinking water. Earlier the packaged drinking water
market consisted of five-star hotels, tourists and foreigners. As a marketing
strategy, a conscious decision was taken by the company that only 40% of the
sales should come from these outlets and 60% from general market, i.e. pinwale,
street shop, general stores and even non-tourists.

The brand name Bisleri is so popular in India that it is used as a generic name for
bottled water.

According to the company’s website, Bisleri invests 10 million liters of rain water
every year. More than just an initiative it’s a clear reflection of Basler’s outlook to
life, whether it’s products, people or profitability. As one of the world’s most
trusted brands, Bisleri is leading the way in bringing about positive change in our
daily lives. Some initiatives involve small communities, others involve the entire
population, but they are both a part of the meaningful revolution called the Aqua
green revolution.

 Vision:

According to the company’s website the vision of Bisleri is: The Aqua Green
Revolution began with an ambitious dream: An India in which every person has
uninterrupted access to scientifically purified and fortified drinking water,
irrespective of geographical barriers or economic limitations.

 MISSION

We must have world class quality, at the lowest production and distribution cost.
This will make us an unbeatable leader, and we will have satisfied loyal
customers.

 Product:

Besides Mineral water, Bisleri also produces Bisleri Soda and Bisleri Vedica
Natural Spring water. The purification process of Bisleri mineral water involves a
six-stage purification process.
In the first stage, the ground water is ozonized to destroy the virus and bacteria.
The next step involves purification by sand filter which removes coarse particles
up to 30 microns in size. A carbon filter is then used to remove color and odor,
followed by Reverse Osmosis to filter harmful minerals and salts. The following
step involves fortification of water with minerals. Finally, the water is ozonized
once more to ensure zero-contamination during packaging and storing. Bisleri
with added minerals is available in 250 ml, 500 ml, 1 liter and 2-liter bottles and 5-
liter, 15 liter and 20-liter jars.

 Promotion:

Bisleri is promoted through TV and print media aggressively. Every opportunity to

interact with the customer is used to promote the product. For example, all the
vehicles used for supply are painted in green, bearing the BISLERI logo and
slogans like “Drink and Drive”. In 2008, competing with the other brands in the
mountain water category, the brand adopted a tv commercial that reflected
spirituality, carrying the tagline “The sweet taste of purity”. The company has also
started a new campaign called “Stay Protected” which is an extension of their
own earlier “Play Safe” and the television commercial concentrated a bit more on
the protection aspect.

 Distribution:

Bisleri currently has 25 bottling units and about 5000 vehicles for distribution.
Throughout the country, Bisleri has about 3,50,000 retail outlets. Manufacturing
operations are done in 18 places in India. For the 20-liter jar, the company has
introduced a home delivery system which is done by a specialized distribution
system. Bisleri distributes in 3 phases:

1. Direct distribution through roadways

2. Through Local distributors to retail outlets.
3. Home delivery with the help of small depots inside cities

Bisleri - Net Worth

Water scarcity has been a great issue in India, furthermore, bucolic struggles
regarding water supply especially for cultivating the crops as well as needed water
to cook for themselves. On the other hand, millions of people are affected by
Water-borne diseases in India each year. This situation was considered by the
Bisleri company and worked on. According to the reports, Bisleri company net
worth is estimated at 3000 crores in rupees. Now the company has been growing
at 40 per cent annually where each day the sales turnover is claimed to be 15
million bottles all over the world.

Bisleri established 104 branches not only in its home country but also in
neighbouring countries. Furthermore, Bisleri implemented its plant in Singapore
and Japan and now slated to enter Sri Lanka, Bangladesh and other Middle-east
countries to enlarge the business on a large scale. But the expansion of the
company held a pause as there is sufficient manpower to enter a global business.

Bisleri - Marketing Strategy

Despite the increasing competition in the packaged drinking water industry,

Bisleri holds the largest market share of 36%. Even though Bisleri has diversified
its products, it is widely known for its packaged drinking water. The company uses
the 4P’s of marketing to keep its consumers satisfied and also increase its
customer base.

Product Strategy:

Bisleri’s packaged drinking water is the main component in the marketing mix of
Bisleri. Packaged drinking water is available in different quantities and return is
available only for 20L and 5L packs. The other products offered by Bisleri include
soda, which is carbonated water used to make combination drinks; vedica, the
natural mountain water that has detoxifying agents; pop, a carbonated soft drink
that comes in four flavours and urzza, a caffeine-free power drink that helps
overcome fatigue by stimulating the mind.
Pricing Strategy:

Bisleri’s products are affordable and offer more quantity with less cost. Bisleri
uses location-based pricing strategy. Bisleri’s products sold in restaurants,
theatres, etc are costlier compared to retail shops.

Place & Distribution Strategy:

Bisleri maintains a solid supply chain with a fast distribution system. Even though
the company’s head office is located in Mumbai, Bisleri has 15 plus manufacturing
units across the country leading to large scale production and the company’s own
distribution network in the manufacturing cities makes access to products easier.
Bisleri also owns a large number of trucks that makes smooth and fast
transportation possible.

Promotion Strategy:
Bisleri has adopted several forms of promotional activities from advertising on
television, print forms to personal selling and usage of billboards, posters and
hoardings. The brand also has a complete website detailing its various products.
The famous one-liner ‘Biasleri is veri veri extraordinari’ in Bisleri’s first
advertisement has captured the attention of a substantial number of consumers.
The different campaigns Bisleri has initiated have given the brand a great deal of
exposure. Notable campaigns include the ‘one nation, one water’ where labelling
was done in different languages to connect with people from different regions;
‘Har Pani ki bottle Bisleri Nahi’ where they promote the idea that not all water is
pure and hygienic like Bisleri.

Bisleri’s growth from 1969 to 2021 is magnificent. The growing number of its
customer base and the brand ability to maintain its lead in the industry speaks for
itself in terms of the success of the brand. The unwavering quality and
affordability of Bisleri’s products are the main reasons for the brand to defend its
place as a key player.

Bislari product lists

 CHAPTER - 1
INTRODUCTION
Food Science and Technology is a discipline that combines the study of science
and engineering to process, evaluate, package and distribute food. Food science
examines everything that can happen to food between harvest and consumption.
Food technology is used to develop and manage the processes by which food is
transformed from raw harvest to edible goods purchased by individual
consumers. With the aid of various disciplines in food science and technology, raw
materials are being converted to edible foods. Reduced diseases, improved safety
and quality, variety, less cost, less wastage is some of the advancements in the
field.

Water is the only substance on the Earth that occurs in all three physical states
simultaneously (solid/ice, liquid/water, and gas/water vapor). It is an essential
material for life: living systems consist of water and its amount is about 70–80% .
Water possesses many chemical and physical properties that make it useful to
cells and organisms. It is a medium for the majority of biochemical reactions.

Water is a nutrient in food groups: grains, meats, dairy products, fruits, and
vegetables. Major nutrients such as carbohydrates, proteins, water-soluble
vitamins, and minerals are hydrophilic. Most of carbohydrates and proteins in
foods are plasticized by water. A part of lipid components are hydrophilic,
whereas another part of lipid and protein components are hydrophobic and
experience from hydrophilic effect in an aqueous environment. Water interacts
with other food components by means of polar, hydrogen-bonding, and
hydrophobic interactions. These interactions change the properties of water.

Water plays many critical roles within the field of agriculture, food, and feed
science, technology, and engineering. Water is the main components of drinking
water, beverages and most of foodstuffs. Water content of fresh fruits,
vegetables, meats, and sea foods exceeds 50%. Water is used as a good medium
to cook foods. In addition, steam is the basic working medium of heat (as a feed
for boiler) and power engineering in food processing. In food chains, water is not
just a medium for reactions, but is also an active ingredient used to control
reactions, food texture, and physical and biological behavior. Food may pick up
moisture from the environment or lose moisture to the environment during
storage. The percent of loss of fresh foods can be significantly reduced by
controlling their water activity during storage. These changes may influence the
texture and organoleptic properties of foodstuffs. Many operations in food
processing (concentration, drying, dehydration, thawing, salting, and freezing) use
physio-chemical properties of water and its state transition properties.

Significant amounts of information on the properties of water are available in the

literature. The information and its importance to food technology are dispersed
and fragmented. The objectives of this study are to describe various properties of
water, to discuss the effects of water properties on individual food components
and combined foods, to describe its importance to food technology, and to
compare properties of water with corresponding properties of similar substances.
Several properties of water (boiling and melting points, heat of fusion, heat of
vaporization and sublimation, heat capacity, thermal conductivity, surface
tension, and viscosity) have been compared with similar substances. The
information given in this study can be used for processing, storage, and packaging
of beverages and foodstuffs.

VISCOSITY

Viscosity and thermal conductivity are two of key transport properties. Dynamic
viscosity (measure of internal fluid friction, i.e., resistance to deformation) of
water is greater than that of comparable substances without hydrogen bonds.
The viscosity drops dramatically with an increase in temperature the dependence
can be described by a conventional Arrhenius-type expression.

Pure water and aqueous solutions containing low-molecular weight solutes such
as salts and sugars under normal conditions are Newtonian fluids (shear stress is
directly proportional to rate of deformation or rate of shear strain). There is a rise
in viscosity when a nonvolatile substance is dissolved in water. In general,
aqueous solutions contain large-molecular weight food components (proteins,
polysaccharides, hydrocolloids), even though only small amounts are non-
Newtonian.

SOLUBILITY OF MATERIALS IN WATER

Water is a universal solvent as well as a solvent for many substances because of

strong interactions between water and other substances, its high dipole moment,
and its ability to donate and accept protons for formation of hydrogen bonds.
These properties make it an excellent solvent, especially for electrolytes and polar
compounds (salts, acids, sugars, alcohols, carbonyl compounds, etc.).] More than
half of known elements in the periodic table can be found in natural water, some
in high concentrations, and others only in trace amounts. Water has been called a
green solvent. It is a safe solvent and has advantages over polluting organic
solvents due to the environmental concerns.

Water is used as a solvent or diluents in preparation of beverages and foodstuffs.

A foodstuff ususally contains various organic and inorganic substances. These
solutes modify the properties of water. At ambient temperature and pressure, the
food components (carbohydrates, proteins, minerals, acids) are miscible in water,
while lipids have fairly little interactions with water.

The physical properties of water (e.g., boiling and freezing points) are affected by
solutes such as salts and sugars in water, beverages, and foodstuffs. One mole of
sucrose per kilogram of water raises the boiling point of water by 0.51°C, and one
mole of sodium chloride per kilogram raises the boiling point by 1.02°C. Similarly,
increasing the number of dissolved particles reduces the freezing point of water.
For example, it is −8.4 and −16°C for 7% solutions of K2SO4 and NaCl, respectively.
Freezing point depression of water is related to water activity. Freezing point
depression is used to check for adulterations of milk. This property of water can
be also used to verify for adulteration of other beverages and foods. Adsorption,
extraction, filtration, and osmotic procedures can be employed to remove several
contaminants from both ground and surface water. Drinking water may also be
prepared when salty water freezes. The drinking water produced from the latter
procedure is almost pure, and it contains only very little salts.

WATER CONTENT AND WATER ACTIVITY

Water, as a constituent of food, may affect food safety, stability, quality, and
physical properties. Range of water concentration (or water content: the amount
of water in a food per amount of its dried food) in food is very broad and begins
with a fraction of a percent and reaches even more than 98%. Fresh and liquid
foods contain usually large amounts of water while baked and dried foods are
poor in water content. In food products with high water content, such as fresh
foods, water loss alters physical characteristics and water gain leads to favorable
conditions for microbiological growth. Thus, food packaging is performed against
gain or loss of water.

The definition of aw is

where p is the partial water vapor pressure in equilibrium with the solution,
and p* is the (partial) vapor pressure of pure water at the same temperature.

An alternate definition can be

where lw is the activity coefficient of water and xw is the mole fraction of water in

the aqueous fraction.
Water activity is used in many cases as a critical control point for Hazard Analysis
and Critical Control Points (HACCP) programs. Samples of the food product are
periodically taken from the production area and tested to ensure water activity
values are within a specified range for food quality and safety. Measurements can
be made in as little as five minutes, and are made regularly in most major food
production facilities.
For many years, researchers tried to equate bacterial growth potential with water
content. They found that the values were not universal, but specific to each food
product. W. J. Scott first established that bacterial growth correlated with water
activity, not water content, in 1953. It is firmly established that growth of bacteria
is inhibited at specific water activity values. U.S. Food and Drug
Administration (FDA) regulations for intermediate moisture foods are based on
these values.
Lowering the water activity of a food product should not be seen as a kill step.
Studies in powdered milk show that viable cells can exist at much lower water
activity values, but that they never grow. Over time, bacterial levels decline.

Water is an essential component of foods. It combines with food components

(protein, carbohydrates, phospholipids, water-soluble vitamins, etc.) by means of
polar, hydrogen bonding, hydrophilic, and hydrophobic interactions. Among the
various types of intermolecular interactions, the hydrogen bond plays the most
significant role in determining the structure and properties of water and food
components. A high value for dipole moment and contribution of hydrogen bonds
in water associations are responsible for its several unusual properties. Free
energy of cohesion for polar and van der Waals contributions represent 70 and
30% of the total energy for the liquid water, respectively. The effect of hydrogen
bond formation is central to understanding unusual properties of water. The
structure and properties of water change based on its state, temperature, and
pressure. The properties of water in foods are different from those of pure water.
Knowledge on the properties of pure water is a prerequisite for understanding
their effects on other individual food components and combined foodstuffs. The
quality and cost of foodstuffs depends strongly on their water content and water
activity. Water plays important roles in many technical processes and its
properties are used in a wide range of food technologies. The rate of chemical
and biochemical reactions can be controlled by water activity, pH, and
temperature. Storage, shelf-life, stability, and microbial safety of foodstuffs
depend on their water content and water activity.

Mineral water
Mineral water is called mineral water because it contains dissolved solids, gases,
and minerals in it; the following minerals may be found in mineral water in
varying degrees-

 calcium
 Potassium
 Sulfate
 Hydrogen carbonate
 sodium
 bicarbonate
 iron
 Zinc
 Magnesium

and gases like

 Carbon dioxide
 Hydrogen sulfate

advantage

1. Aids in lowering blood pressure

People with a low amount of magnesium in their body may fall prey to heart
issues like hypertension and blood pressure; hence it is required that you take the
optimum amount of magnesium required to keep your heart healthy.

Mineral water contains a good amount of magnesium and helps in reducing blood
pressure and improving overall heart health.
2. Helps in regulation of blood circulation

Calcium, magnesium, and potassium present in mineral water help regulate the
rhythm of your heartbeat and aid in better blood circulation . Helping improve
your body’s functioning.

3. Bone strengthening

Calcium is an essential mineral found in mineral water that helps keep your bones
healthy by increasing bone density and supporting bone strengthening. Low bone
density can cause your bones to become brittle and weak, primarily seen in
women above the age of twenty. They can drink mineral water to keep up the
supply of calcium in their bodies.

4. Provides benefits to the skin

Mineral water contains minerals like zinc, copper, and magnesium, which help in
keeping your skin healthy, zinc is anti-inflammatory and antibacterial; magnesium
helps in keeping the skin healthy, and copper helps in the regulation of collagen
hence helping you gain healthy, shiny skin.

5. Increases magnesium

Magnesium is an essential mineral required by the body for nerve functioning,

regulating blood pressure, and maintaining optimum glucose levels. An average
human will require 310–320 mg of magnesium for females 400–420 mg
magnesium for males; mineral water can contain upto 150 mg of magnesium per
litre of water depending on the source it is obtained from.

6. Promotes better digestive health

Mineral water can be very beneficial to people who suffer from stool-related
conditions like constipation and indigestion. Mineral water contains magnesium
which helps in water retention in the intestine improving stool consistency. The
magnesium and sodium sulfate also help relieve the muscles of the intestine to
help improve your bowel movements and improve the functioning of the
gallbladder.

Disadvantage
Though filled with advantages, mineral water has some disadvantages; most of
these disadvantages are because of the modern bottling methods of mineral
water; you could avoid them if you can source pure mineral water directly from a
trustable source.

1. Risk of plastic toxicity

Mineral water is usually made available commercially in plastic bottles; plastic

bottles may contain chemicals like BPA and bisphenol A which interferes with the
functioning of hormones in your body and, in dire cases, affect your reproduction.

Another concern is microplastic contamination caused by the small pieces of

plastic; though the risk of this is not high, it is present.

2. Damages teeth enamel

Though mineral water causes less damage than carbonated drinks, regular
consumption might pose a threat to your teeth’ health. Mineral water has a
slightly lower pH than regular water; this makes it slightly acidic in nature which
will corrode the topmost layer of your teeth known as enamel. This might damage
your teeth and make them more prone to cavities.

3. Environmental damage

Mineral water is packaged in plastic bottles, which are detrimental to the

environment. Plastic is non-biodegradable in nature, and it takes the earth a long
time to be able to decompose it; hence it causes pollution. Overflowing landfills
filled with plastic bottles are also a growing concern.

4. Risk of microbial infection

As mineral water is bottled at the source without undergoing any treatment, it

may have various microbes and organisms that may cause you harm. Also, the
carbonic acid present in carbonated water can cause hiccups or bloating.

5. Harmful for people on a low sodium diet

Drinking mineral water is generally safe for most people, but people who are on a
low sodium diet should stay cautious. Some brands of minerals water have a large
amount of sodium added to them, which can be detrimental to some; check with
your doctor if you are unsure.

BISLARI HIMALAYN

GOOD MANUFACTURING PRACTICES

PURPOSE:

To provide requirements for Good Manufacturing Practice for Packed Drinking

Water manufacturing facilities for compliance to Regulatory and company
requirements and also to ensure manufacturing facilities are periodically assessed
and are maintained in compliance With Good Manufacturing Practice
requirements

SCOPE

All Packaged Drinking Water manufacturing facilities are required to follow the
Good Manufacturing Practices

GMP GUIDELINES:

SITE SELECTION

Select a site that protects the plant from outside contamination and
Environmental influences.

PREMISES

 Design and construct the plant and ground to prevent contamination from
entering the plants from outside area.
 Design and construct the plant and grounds to eliminate standing water.
 Design and construct the plant and grounds to keep insects, vermin, and
other pests from entering the plant.
 Design the storage and handling area to prevent possible contamination.
PROCESSING AREA

 Protect processing area from contamination from other parts of the plant.
 Prevent the contamination of finished products, raw materials, ingredients,
and packaging materials.
 Supply enough drainage to prevent standing water and odor’s

GENERAL GUIDELINES TO BE FOLLOWED IN THE PROCESSING AREA

 Filling area should be separate from packing area. The Filling area should be
properly ventilated with sufficient exhaust fans.
 Exhaust fans should be checked that they are wired correctly and that the
fan is moving in the correct direction and the exhaust air is being blown
out. A simple method to check this would be to attach a rib bon on a stick
and affix it on the exhaust fan in the front
 All equipment and utensils which is in direct contact with product water
should be made up of SS 316.Preventive maintenance of equipment is
performed as per schedule and recorded. Machines are in proper working
condition.
 Ensure confect plugs for sockets are used and no tapping is done using bare
wires.
 Online defect monitoring system is followed. The on-line Inspector check
the packs and removed achieve packs. The defective packs are reviewed by
production and QA supervisors, The reason. For defects is found out and
appropriate corrective and preventive measures are taken to remove-the
defects.
 Each pack of finished product is properly coded to allow product
traceability, Coding should contain shift number; date, month, year of
manufacturing, time and Initials of shift supervisor and quality inspector
 Permanent, legible and dated records of processing and production details
for each batch / lot to be maintained. These records are retained for a
period up to the shelf life plus three years.
  Floors, walls, ceilings should be smooth, without cracks, crevices, paint
peelings, cobwebs and easy to clean. Angles between walls and floors
should be smooth, sealed and curved to facilitate cleaning. Doors should
have smooth surfaces and to be kept close when not in use. Windows
should be closed and with screens to avoid entry of insects.

 All Returnable pack sizes should come back from the Market to the Plant
with the caps on them. This is to prevent foreign matter from entering into
the jars while they are being stored in various places before they reach the
Plant. Cleaning will thus be much easier if the foreign matter has been
prevented from entering in the first place. Neck of the jar will also be
protected from damage.

CLEANING AND SANITIZATION.

 Cleaning and sanitizing (disinfecting) are usually 2 separate processes.

Effective cleaning must occur before sanitizing. Cleaning is not intended to
destroy microorganisms, sanitizing is required for this purpose.
 Sanitizers are substances capable of destroying microorganisms including
those bacteria that cause food poisoning and other diseases.
 When used properly, they can reduce surface contamination by bacteria to
a safe level. It is important to read and follow the directions on sanitizers
carefully.
 Sanitizing is usually achieved using heat and water, or chemicals, or a
combination of both methods. An effective alternative to chemical
sanitizers is hot water used at (75°C or hotter) to soak items for 2 minutes
or more.
 Before work is commenced and after it is finished all the machines should
be cleaned and sanitized and the floor should be kept clean

STORAGE AREA
Design storage areas (ambient temperature) to prevent contamination or
degradation of material and finished products.

Store ingredients in clean area to prevent degradation and contamination.

STORAGE AREA OF AUXILIARY MATERIALS

• Prevent contamination of product, ingredients, and other packaging materials.

WATER TREATMENT AREA

Design and construct the water treatment area to prevent contamination.

Design and construct the water treatment area to provide sufficient drainage to
prevent standing water and odors.

EQUIPMENTS, PIPING. AND UTENSILS

 Ensure that equipment, pipe work, and utensils in contact with finished
products are inert to the material handled, easily cleaned, and self-draining
 Install equipment's and pipe work to prevent contamination of ingredients,
and finished product.
 Install equipment's and pipe work to avoid the possibility of cross-
contamination of products, cleaning or sanitizing agents.
 Install equipment's and pipe work to supply enough space for cleaning.

UTILITIES

 Install and equip lighting fixtures, skylights, or other utilities, to prevent

contamination.
 Install enough lighting throughout the plant to ease cleaning and processing
activities.
 Install, operate, and maintain ventilation systems to prevent contamination
of products, ingredients, or packaging from condensation, dust, debris, or
odors.
 PERSONNEL FACILITIE

 Everyone working in direct contact with food, food-

contact surfaces and food packaging materials must
follow hygienic behavior.
 Any behavior or unhygienic practices which could result in contamination
of food shall be prohibited in food processing, distribution, storage and
handling areas. This includes smoking, chewing or eating, Sneezing or
coughing over unprotected food, spitting etc.
 Personal effects such as jewelry, watches, pins or other items should not be
worn or brought into food handling are as if they pose a threat to the safety
and suitability of food
 Supply sanitary equipment and produces for plants workers.
 Provide toilets designed and located so they don't contaminate ingredients,
or finished product
 Post hand-wash signs requirement in all toilet facilities.
QUALITY CONTROL LABORATORY

Build a quality control laboratory that doesn't contaminate ingredients, raw

materials, and finished products during analysis.

Equip room used for microbiological testing with clean and filtered air/AC.
Provide utilities to support activities and keep test results accurate.

PACKAGING MATERIAL, STORAGE AND HANDLING

PURPOSE: To provide storage and handling requirements for packaging materials
to protect the quality of packaging material during storage before use in
production for units manufacturing Packaged Drinking Water.

SCOPE: The storage, handling and transportation requirements for packaging

material applies to all Packaged Drinking Water manufacturing locations and
storage and handling requirements of PET applies to all PET jar manufacturing and
distributing locations.

REQUIREMENTS:
GENERAL:

 All the receiving material should be purchased from authorized suppliers.

 All consignments of Incoming materials will carry a Certificate of Analysis
from the supplier.
 Incoming material shall be visually inspected for tamper evidence, damage
and abnormal odors.
 Storage of receiving material before testing and release shall be done at the
designated locations (Quarantine Area) and approved material only
transferred to appropriate storage conditions after QA checks/acceptance.
 Identification of Material status for Passes, On Hold and Rejected should be
implemented and stock & status updating should be done.
 Plant should have demarcated covered controlled storage area for all the
raw materials primary and secondary packaging material. The storage area
must keep free from debris and spillage.
 Records should be maintained for handling and storage of Packaging
materials.
 All rejected materials will be marked REJECTED on each and every
carton/bag to avoid any accidental use.
 Ensure that incoming materials are coded with the date of receipt and date
of manufacturing at the supplier end or supplier lot no.
  Inventory management should be controlled by maintaining monthly stock
updates.
 Implement inventory rotation using First In First Out (FIFO) & First Expired
First out (FEFO) principle.
 Ensure protection from damage, deterioration, and contamination from
foreign matters, insects, dust and rodents and follow good manufacturing
practices.
 Operate in compliance with GMP requirements.
 Restrict the storage area to authorized persons.
 Use packaging material only for its intended purpose.
 Before and after unloading shipping containers, inspect the vehicles foe
cleanliness, off-odors, that may have contaminated the packaging
materials.
 Store packaging material indoors in a sanitary manner.
 Storage area must be well ventilated, free from dust, and free of truck and
forklift exhaust fumes. Poor storage condition cause excess rejects.
 Storage area must be protected from direct sunlight and from
temperatures exceeding 40°C.
 Containers for products for human consumption, and containers for
ingredients for these products, should never be used to contain non-food
substances be clearly marked and at least 18 inches should be at least a tall
between paella stacks and walls

STORAGE AND HANDLING OF PET PREFORMS:

  Shoe preforms in a covered / encased area (roofed) to prevent entry of
dust
 keep fee passage for proper air ventilation between the stored pallets.
 Avoid contact with water to prevent contamination and moisture
absorption by the preforms.
 Keep the preforms in hygienic conditions to prevent contamination
 Stack pallets in such a way to prevent any damage to the boxes or the
preforms
 Align tine pallets properly so that the corners of upper pallet rest on the
corner of the lower box.
 Use pallets which are free from any materials that could transfer an off-
taste or odor to bottles.
 Store the base/ partly used preforms in the box with polythene liner and
seal the box perfectly.
 Keep the material in the original packaging as far as possible. Consume
these materials at the next immediate production.
 In case of damage to the original packaging, transfer the preforms
hygienically to another undamaged box having polyethene liner and seal
the box openings.
CLOSURES, CARTONS, AND SLEEVES

 Ensure that the closers, sleeves and labels are in sealed plastic or paper
bags inside a suitable container to protect the material against
contamination or deterioration.
 Store closers in a dedicated storage area with restricted access that is
clean, well-ventilated and insect and rodent-proof.
 Cartons and sleeves should be stacked on pallets or racks, and sufficient
spaces should be left between stacks and walls to allow adequate air
circulation.

LABELS
 Protects labels from extreme temperature conditions and high humidity.
Labels are sensitive to changes in temperature and humidity and hence
should be packed in protective moisture resistant containers and stored in
separate, dedicated areas.
 Racks or pallets should be provided to keep containers of the labels off the
floor and to avoid distortion from stacking.
Plant Warehouse

 Returnable Jars should be stored in a separate part of the plant to avoid

contamination of non-returnable containers and finished product.
 Keep the empty jars in a cool, dry place away from sunlight and in such a
way to prevent contamination from foreign matters, insects, dust, and
rodents.

PEST CONTROL PROGRAM

To provide standards on Pest Management Program for plants by Use of at

approved licensed professional pest from use of least toxic pest control
techniques and products at also provide guidelines to prevent cross
determination of products with pesticides while application, for pest
control activity.

SCOPE

Must be followed by all Packaged Drinking water manufacturing facilities.

POLICY
 General Good hygiene practices are being employed to avoid creating an
environment conductive to pests. Good sanitation, inspection of incoming
materials and effective monitoring can minimize the likelihood of
infestation and thereby limit the need for pesticides.

 Pest control treatment should be done to control flies / insects, rodents,

birds and other pests. Insecticides are used carefully to avoid any chance
contamination with product water, source water or contact equipment.

 The production area should be free from any pests such as rodents, insects,
flies, cockroaches, birds, etc. Adequate numbers of Fly catchers are present
in the plant. Fumigation of plant to be done as per schedule to avoid
microbial contamination.

 All pest control activities should be done by expert pest control contractor.
Details of chemicals being used along with MSDS are available.

 Plant interiors if using a trap or bait devices will use only glue traps or non-
toxic physical methods. The dead destroyed pests will be captured and
removed from site by Pest Control Contractor after recording the relevant
data in the log sheets.

 No pesticides shall be applied to finished products.

 The pest control activity shall be carried out only during non-production
hours.

 Records duly signed by applicator and QA person must be maintained every

time an application of pesticide is carried out.

Preventing Access:
  Buildings should be kept in good repair and condition to prevent pest
access and to eliminate potential breeding sites.

 Holes, drains and other places where pests are likely to gain access should
be kept sealed. Where sealing Is not possible (e.g. open windows, doors
and ventilators) measures like wire mesh screens are be in place to reduce
the problem of pest entry.

 Birds/ animals should be excluded from the grounds of factories and

processing plants.

Harborage and Infestation:

 Potential product sources should be stacked above the ground and away
from walls.
 Areas both inside and outside product premises should be clean.

Monitoring and Documentation:

 Records should be available to demonstrate the pest control activities and

bait replacements.
Eradication:

 Pest infestations should be dealt with immediately and carried out without
posing a threat to the safety or suitability of product.
Hazard analysis critical control point (HACCP)

Hazard - Biological, physical Chemical agents in the food or condition of food

with potential to cause an adverse health effect
HACCP – Is the latest quality assurance technique to remove the hazard for
product safety at different stages of production to keep product safe for
consumption
Critical Control Point – It is a point at which control can be applied and is
essential to prevent or eliminate food safety hazards or reduce it to an acceptable
level
Principle 1 - Conduct a Hazard Analysis. ...

Principle 2 - Identify the Critical Control Points. ...

Principle 3 - Establish Critical Limits. ...

Principle 4- Monitor CCP. ...

Principle 5 - Establish Corrective Action. ...

Principle 6 - Verification. ...

Principle 7 - Recordkeeping. ...

Standard operating procedures (SOP)

Foodservice Industry standard operating procedures (SOPs) are written practices
and procedures of how your establishment will produce safe food. SOPs are a key
component to your overall food safety program. SOPs include specific details of
how a policy will be implemented including: Who will perform the task.

Audit
Audits play a key role in verifying proper food safety practices at food and
beverage processing facilities. Audits are a planned, independent, and
documented assessment to determine whether agreed-upon requirements are
met, and the food industry relies on the audit function to provide safe food to
their consumers.
A team of internal auditors has been formed under the leadership of the
management representative. The management representative does the planning
and coordination of execution of internal audit. The audit team members are
trained on the methodology of quality auditing and such training records are
maintained. Internal audit plans are made and audit is executed in accordance
with such plans. The personnel independent of the areas being audited and
corrective actions decided carry out audit. Non-conformities observed are
brought to the attention of the person responsible for the area being audited and
subsequently audit reports are considered during management review meetings
where the implementation status of corrective actions is also reviewed. Two
types
Internal Audit:
It is done once in 6 months by the trained personnel of the company.
External Audit:
It is done by the external authorized auditing department.
Documentation and Record keeping
 Documents are created as a part of organizational planning. It is originated in
the planning phase of the Plan, Do, Check, Action (PDCA) cycle. A document
consists of any information that we use to run the company.
 Appropriate records of processing/production, storage, distribution, food
quality, laboratory test results, cleaning and sanitization, pest control and
product recall shall be maintained
 Ex – Food safety manual, Approved supplier list, Product specification, Food
safety Manual, ISO Manual.
 Records shall be retained in a good condition at least for a period of one year
or the shelf life of the product, whichever is more.
Maintenance o Preventive maintenance programs must include all devices used
to monitor and/or control food safety hazards and cover the maintenance
activity. It shall be carried out regularly as per the instructions of the
manufacturer
 Corrective maintenance shall be carried out in such a way that production on
adjoining lines or equipment is not at risk of contamination and post
maintenance verification to be get recorded. Internal and external calibration
schedule for critical food safety equipment’s should be maintained
 Lubricants, heat transfer fluids or any other similar material used shall be food
grade where there is a risk of direct and indirect contact with the product
 It is recommended as best practice to maintain plant equipment’s breakdown
records o Loose items control policy (Nut & bolts, Nails broken pieces or
smaller parts of machines) should be followed to prevent any contamination
with product or packaging material.

Cleaning and sanitization

Clean-in-place (CIP) of equipment:
 CIP is a method of cleaning the interior surfaces of pipes, vessels, process
equipment, filters and associated fittings, without disassembly
 It is done before production and after production using hot water o Hot
water along with peroxide CIP is done once in 15 days
Dry and wet cleaning method
 Dry cleaning involves the use of tools such as vacuum cleaners, brooms and
brushes
 Water is used for wet cleaning method. It is followed by disinfection to
inactivate microorganisms. Disinfectants that will rapidly evaporate such as
alcohol-based disinfectants, provides a means to spot disinfect equipment
with a very minimal introduction of water. It is followed by drying.
Fumigation

 Fumigation is a method of killing pests, termites or any other harmful living

organisms to prevent transfer of exotic organisms.
 Here fumigation is done using formaldehyde and potassium permanganate

Manufacturing Operations
 Food manufacturing covers the processes involved in production from raw
material to final product.
 Operations in processing food products are extremely varied from one
industry to another.
Analysis of incoming raw material
 Raw materials are accepted from the approved
suppliers.
 Tests are done to see whether the incoming raw material meets the standard
specification also the raw materials are visually inspected.
 The inspection should cover the vehicle condition, whether it has any holes
and/or water damage, any consideration caused by the varying temperature
zones the product may have gone through while being delivered, any damage
to product packaging, any type of contamination to the packaging, checking
that there are no non-food items on the truck, no dead/live insects, no
allergen material etc.
 Based on the inspection result incoming materials need to be categorized as
accepted or rejected.
• Rework and control of non-confirming product o Nonconforming Product is
product that does not fulfil its specified requirements. Nonconformances can
occur in both product and process. Nonconforming processes can lead to
nonconforming product. o Manufacturer establishes and maintain procedures
to control product that does not conform to specified requirements….
o The organization establishes and maintains documented procedures that
specify appropriate actions to identify and eliminate the cause of detected
non-conformities, to prevent recurrence, and to bring the process or
system back into control after non-conformity is encountered.
o Handling of rework/Add back – to be done in such a way to avoid cross
contamination during processing, handling and storage
o Rework is clearly identified and/or labelled to allow traceability o
Traceability records for rework is maintained and is always approved by QA
department

• Food transportation and distribution o Vehicles of only FSSAI registered

transporters shall be used for transportation.
• The dispatch of finished goods must follow FIFO or FEFO system.
• Conveyances and/or containers used for transporting is kept clean and
maintained in good repair condition to protect from contamination
• All vehicles are properly covered with tarpaulin and the finished product
boxes are kept at prescribed max. height to avoid damages.

Food traceability and recall

•A recall is identified after the initial investigation of reported incident at

manufacturing unit or complaints/received from consumers or any other
sources.
 A system/written procedure is placed to enable the recall of any lot of
product and provide detailed information to assist in the investigation of any
identified procedure contamination.
Quality control
This organization have a quality control programmed in place to include
inspection and testing of incoming products in process and finished products
o All incoming raw materials/packaging materials /food
additives/ingredients test records or certificate of analysis (COA) is
maintained. Adulteration tests defined under FSS regulation is
performed with each lot

Quality Assurance and Quality control

Quality control: Quality Control” is a somewhat reactive approach based heavily

on inspection to find defects before the product is ready for release or shipment
or at the end of selected stages in the development or manufacturing process.
Quality Control is product oriented. QC is testing checks the quality of a product
and it classifies under the domain of QC. When you are testing a product for
quality, you are not assuring its quality, you are controlling it.

Quality assurance: “Quality Assurance” is a much broader and more proactive

approach that attempts to go upstream in the process to eliminate defects at the
source. The goal of an effective Quality Assurance effort is to design processes
and systems that are inherently reliable in producing high-quality products.
“Quality Assurance” takes a holistic approach to identifying and trying to
influence all the factors that might have some impact on the quality of products
including the role of people in producing those products. An effective Quality
Assurance effort can significantly improve the level of quality over a Quality
Control approach because a Quality Control approach is based heavily on
inspection and sampling to find defects and it would be very expensive and
impractical to do 100% sampling. An effective Quality Assurance effort can also
reduce costs by reducing the need for inspectors that are required to find defects
after the product is built.
Quality Assurance is process oriented. QA makes sure that what you are doing
are right things in the right manner. The QA department relies largely on the
feedback it receives from the QC department. If there are any problems, the
same are conveyed by QC department to QA department which makes suitable
changes in the process so as to avoid these problems in future.

Certifications:
International organization for standardization (ISO)

The International Organization for Standardization is an independent, non-

governmental organization, the members of which are the standards
organizations of the 164-member countries. It is the world's largest developer of
voluntary international standards and it facilitates world trade by providing
common standards among nations. More than twenty thousand standards have
been set, covering everything from manufactured products and technology to
food safety, agriculture, and healthcare.
Function

ISO releases certain standard for Industry and by use of the standards aids in the
creation of products and services that are safe, reliable, and of good quality. The
standards help businesses increase productivity while minimizing errors and
waste. By enabling products from different markets to be directly compared, they
facilitate companies in entering new markets and assist in the development of
global trade on a fair basis. The standards also serve to safeguard consumers and
the end-users of products and services, ensuring that certified products conform
to the minimum standards set internationally.
Standards
International Standards are the thing which gives certain instructions to company
to help them maintain good hygiene and safety.
They give world-class specifications for products, services and systems, to ensure
quality, safety and efficiency. They are instrumental in facilitating international
trade.
ISO has published 23037 International Standards and related documents,
covering almost every industry, from technology, to food safety, to agriculture
and healthcare. ISO International Standards impact everyone, everywhere.

ISO Standards used in food industry

• ISO 22000
• ISO 9001
• ISO 14000
• ISO 45001
• ISO 17025

ISO 22000:2005 is a standard dealing with food safety. It specifies the necessity
of food safety management system for the organizations representing a food
chain such that they could validate its ability to control food safety hazards in
order to ensure that food is safe at the time of human consumption. ISO 22000
integrates the principles of the Hazard Analysis and Critical Control Point
(HACCP) system and application steps developed by the Codex Alimentarius
Commission. By means of auditable requirements, it combines the HACCP plan
with prerequisite programs
During hazard analysis, the organization determines the strategy to be used to
ensure hazard control by combining the prerequisite programs and the HACCP
plan, thus providing safe food.
ISO 9001 is defined as the international standard that specifies requirements for
a quality management system (QMS). Organizations use the standard to
demonstrate the ability to consistently provide products and services that meet
customer and regulatory requirements. ISO 9001 helps organizations ensure their
customers consistently receive high quality products and services, which in turn
brings many benefits, including satisfied customers, management, and
employees.

ISO 14000 is a series of environmental management standards developed and

published by the International Organization for Standardization (ISO) for
organizations. The ISO 14000 standards provide a guideline or framework for
organizations that need to systematize and improve their environmental
management efforts. The ISO 14000 standards are not designed to aid the
enforcement of environmental laws and do not regulate the environmental
activities of organizations. Adherence to these standards is voluntary. ISO 14001
specifies the requirements of an environmental management system for small to
large organizations. An EMS is a systemic approach to handling environmental
issues within an organization.

ISO 45001 is an International Standard that specifies requirements for an

occupational health and safety (OH&S) management system, with guidance for its
use, to enable an organization to proactively improve its OH&S performance in
preventing injury and ill-health.
ISO 45001 is applicable to any organization that wishes to establish, implement
and maintain an OH&S management system to improve occupational health and
safety, eliminate hazards and minimize OH&S risks (including system deficiencies).
ISO 45001:2018 does not address issues such as product safety, property
damage or environmental impacts, beyond the risks to workers

ISO/IEC 17025 General requirements for the competence of testing and

calibration laboratories is the main ISO standard used by testing and calibration
laboratories. Laboratories use ISO/IEC 17025 to implement a quality system
aimed at improving their ability to consistently produce valid results. For many
internation industries ISO 17025 is mandatory in their lab. It includes factors like
PRP, GMP, OPRP etc.

Food Safety and Standards Authority of India (FSSAI)

The FSSAI has been established under the Food Safety and Standards Act, 2006
which is a consolidating statute related to food safety and regulation in India.
FSSAI was established under this act in the year 2011 to lay scientific standards
for articles of food. One of the functions of FSSAI is to maintain the quality of food
in the country The FSSAI has its headquarters at New Delhi. Act covers the law
that regulate the manufacture, storage, distribution, sale and import of food. As
per the food safety and standards regulation, 2011, all food business operator in
India must have a FSSAI registration or license if they are involved in the
manufacturing, storage, transportation or distribution of food products.

Based on the size and nature of business, FSSAI registration or FSSAI license may
be required. All the manufacturers, traders, restaurants who are however
involved in the food business must obtain a 14 digit registration or a license
number which must be printed on food packages. FSSAI license are of two
types,
• State FSSAI license.

• central FSSAI license.

In order to obtain the license or registration from FSSAI to the food business
operator one can however fill the FSSAI application thus directly with the
government. The process however is long and it thus requires 30 – 60 days to get
completed.