Production Manual

GOLD WATER BOTTLING AND
NON-ALCOHOLIC BEVERAGE FACTORY
Prepared by: PM
Reviewed by: DMD
Approved by: Deputy Managing Director
July, 06, 2020

Addis Ababa, Ethiopia
Company Name:
GOLD WATER BOTTLING AND NON-ALCOHOLIC BEVERAGE FACTORY
PRODUCTION MANUAL
ISSUE HISTORY
Issue No Reason for Revision Compiled by Reviewed by Effective Date
1 Initial Release PM DMD April 2019
2 Revised to implement IMSC DMD Sep 30,2020
integrated Food safety and
quality management system
based on FSSC 22000 FSMS
and ISO 9001:2015 QMS
requirements
REFERENCE DOCUMENTS
Document Number Document Title
ISO 9001:2015 Quality Management system-Requirements, Clause 8.1 & 8.5.1
ISO 22000:2018 Food safety management system requirements ,Clause 8.1
ISO 22002-1 Prerequisite program on food safety
Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM
Created September 21, 2019 Updated: September 30, 2020 Controller: Document Controller Page 1 of 1
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PRODUCTION MANUAL
Table of Contents
ISSUE HISTORY.........................................................................................Error! Bookmark not defined.
1. Abbreviations and symbols...............................................................................................................5
1.1 Abbreviations...................................................................................................................................5
1.3 Definitions........................................................................................................................................6
2. Pre-production operation..................................................................................................................7
2.1 Purpose.............................................................................................................................................7
2.2 Scope.................................................................................................................................................7
2.3 Theory..............................................................................................................................................7
2.4 Responsibility...................................................................................................................................7
2.5 Definition..........................................................................................................................................8
2.6 Related document............................................................................................................................8
3. Resource allocation............................................................................................................................8
3.1 Purpose.............................................................................................................................................8
3.2 Scope.................................................................................................................................................8
3.3 Theory..............................................................................................................................................8
3.4 Responsibility...................................................................................................................................9
3.5 Definition..........................................................................................................................................9
3.6 Related document............................................................................................................................9
4. WATER TREATMENT.....................................................................................................................10
4.1 Purpose...........................................................................................................................................10
4.2 Scope...............................................................................................................................................10
4.3 Theory.............................................................................................................................................10
4.4 Responsibility.................................................................................................................................13
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4.5 Definition........................................................................................................................................13
4.6 Related document..........................................................................................................................13
5. Cleaning, sanitation and personal hygiene........................................................................................14
5.1 Purpose...........................................................................................................................................14
5.2 Scope...............................................................................................................................................14
5.3 Theory.............................................................................................................................................14
5.4 Responsibility.................................................................................................................................14
5.5 Definition........................................................................................................................................14
6. Cap and pre form injection machine..................................................................................................16
6.1 Purpose...........................................................................................................................................16
6.2 Scope...............................................................................................................................................16
6.3 Theory.............................................................................................................................................16
6.4 Responsibility.................................................................................................................................16
6.5 Definition........................................................................................................................................16
7. Rinsing, filling and cap machine.........................................................................................................18
7.1 Purpose...........................................................................................................................................18
7.2 Scope...............................................................................................................................................18
7.3 Theory.............................................................................................................................................18
7.4 Responsibility.................................................................................................................................18
7.5 Definition........................................................................................................................................19
8. Inspection line and date coding..........................................................................................................20
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8.1 Purpose...........................................................................................................................................20
8.2 Scope...............................................................................................................................................20
8.3 Theory.............................................................................................................................................20
8.4 Responsibility.................................................................................................................................20
8.5 Definition........................................................................................................................................21
9. Labeling and group packing...............................................................................................................21
9.1 Purpose...........................................................................................................................................21
9.2 Scope...............................................................................................................................................21
9.3 Theory.............................................................................................................................................22
9.4 Responsibility.................................................................................................................................22
9.5 Definition........................................................................................................................................22
10. Delivery..............................................................................................................................................23
10.1 Purpose.........................................................................................................................................23
10.2 Scope.............................................................................................................................................23
10.3 Theory...........................................................................................................................................23
10.4 Responsibility...............................................................................................................................23
10.5 Definition......................................................................................................................................23
10.6 Related document........................................................................................................................23
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1. Abbreviations and symbols
1.1 Abbreviations
HDPE: High Density Polyethylene

LDPE: Low Density Polyethylene
LLDPE: Linear Low Density Polyethylene
PRP: Pre-Requisite program
PET: Polyethylene tetra phthalate
THM: Tri halo methane
CCP: Critical Control Point
DMD: Deputy Managing Director
CL: Critical Limits
FSMS: Food Safety Management System
IMST: Integrated quality and Food Safety Management System Team
IMSC: Integrated quality and Food Safety Management System coordinator
HACCP: Hazard Analysis Critical Control Point
ISO: International Organization for Standardization
MN: Manual
OPRP: Operational Prerequisite Program
QAD: Quality Department
PP: Polypropylene bag
PRP: Prerequisite Program
SSOP: Sanitation Standard operating Procedure
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1.3 Definitions
Action criterion (3.2)

Measurable or observable specification for the monitoring of an OPRP
Control Measure (3.8)

Action or activity that is essential to prevent a significant food safety hazard or reduce it to an
acceptable level
Correction (3.9)
Action to eliminate a detected nonconformity
Critical control point - CCP (3.11)

step in the process (3.36) at which control measure(s) is (are) applied to prevent or reduce a
significant food safety hazard to an acceptable level, and defined critical limit(s) and
measurement enables the application of corrections
Critical limit (3.12)

Measurable value which separates acceptability from unacceptability
Food safety hazard (3.22)

Biological, chemical or physical agent in food with the potential to cause an adverse health
effect
Measurement (3.27)
Process to determine a value
Monitoring (3.28)
Determining the status of a system, a process or an activity
Operational prerequisite programme - OPRP (3.31)
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Control measure or combination of control measures applied to prevent or reduce a significant
food safety hazard to an acceptable level, and where action criterion and measurement or
observation enable effective control of the process and/or product
Prerequisite program - PRP (3.35)

Basic conditions and activities that are necessary within the organization and throughout the
food chain to maintain food safety
Significant food safety hazard (3.40)

Food safety hazard, identified through the hazard assessment, which needs to be controlled by
control measures
2. Pre-production operation
2.1 Purpose
The purpose of this manual is to have an effective pre-production operation to conduct smooth
production operation in Purified bottled water bottling plant.
2.2 Scope
The scope of these procedures covers all operation of the natural purified water bottling
operation.
2.3 Theory
Production Operations scheduling focuses on everything from the optimal inventory levels to
detailed scheduling (both of machines and people) to meet customer demands of quantity, quality
and delivery. The breadth of its focus may seem overwhelming, yet operations scheduling is
really nothing more than managing the resources of a company to their optimum potential. This
should not be equated with maximum potential. Neither machines nor people can operate at
maximum output for very long before quality suffers.
Focus
Capacity Planning
Capacity planning involves the estimation of what that maximum output is and a formulation of
what the optimal level of production is. This type of focus is on the efficient use of resources
and, at its most basic, looks to match production to customer demand without incurring shortage
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costs or storage costs. Capacity planning, although useful as a framework, is based largely on
assumptions of customer demand and delivery, assumptions that may not always be accurate
2.4 Responsibility
The production manager has an overall responsibility for ensuring this responsibility
2.5 Definition
-
2.6 Related document
 Annual plan
 Monthly plan format
 Weekly production plan format***
Procedures
Responsibility` Action
Production Manager The production manager is responsible to plan

annual ,monthly and daily production plan based on
the company requirement/annual plan and
communicate to the respective parties
Production supervisor Should review the plans and put into action the days
sequence of task s to start production,
3. Resource allocation
3.1 Purpose
The purpose of this manual is to have an effective resource utilization to conduct smooth
production operation in purified mineral water bottling plant.
3.2 Scope
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The scope of these manual covers all operation of the purified mineral water bottling operation.
3.3 Theory
It is very important to have the right quality of raw material at the right quantity and hence due
consideration must be given to the following resource
Direct materials to be received and/or stored
 Natural mineral water

 HDP High density polyethylene
 Pet resin/ poly ester/

 Master batch
HDP AND PET RESIN Deliveries

Every delivery is allocated a separate batch number. Thereafter, every batch is stored separately.
Each batch is marked with the relevant batch number. This enables the end user of the product
traceability back to the raw material producer.
The necessary manpower based on the manpower requirement must be allocated on each
operation before starting operation.
3.4 Responsibility
The production manager has an overall responsibility for ensuring this responsibility
3.5 Definition
HDP- high density polymer
 Store issue voucher
 Store requisition
 Production report forms
 Bin cards
 Production and technical work instruction
Procedures
Production Manager The production manager is responsible to present the
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proper annual material consumption request plan to
procurement department and must follow the progress.
Should present the manpower requirement plan to HR
department
Production supervisor Should request and store the right raw material based
on the planned requirement.
Should assign the proper manpower in each unit
operation
Should keep the necessary material consumption
records and report.
4. WATER TREATMENT
4.1 Purpose
The purpose of this manual is to have an effective water treatment operation to supply water to
natural purified water bottling plant.
4.2 Scope
The scope of these manual covers all water treatment operation of the natural purified water
bottling operation.
4.3 Theory
Water supply
Borehole water is used for all processing operations. Care must be taken that the water supply is
free from substances that may be determinant to human health and is adequately protected from
contamination. Microbial testing of water takes place at least once per year at external
laboratory, and includes tests for:
1. Total Dissolved Solids

2. Heavy Metals
3. Bacteria (Including Coli forms and Faecal Coli forms)
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RAW WATER STORAGE TANK
It is imperative to store water in a tank to avoid process interruption during pump failure and
water will be stored and kept up to standard following the standard sanitation programs for
reservoirs.
SVS silica sand filter
The SVS silica mechanical filter device which consists of layers of sands, fine garments and
other material. It adopts the principle that makes the different sizes of particles in the water
filtered layer by layer. The big particle is removed on the top layer, and the smaller particle will
be removed on the deep layer. This makes the water quality meet the rough filtered standard.
Reduce SDI value, meet further water treatment requirements.
Activated carbon
This equipment can wipe off the peculiar smell, strange colour and some heavy metal like Hg,
Pb, Cd, Zn, Fe, Mn, chrome and etc. That is contained in the water. It can get rid of arsenic,
hydride, redundant chlorine and other macromolecule compound and radioactivity substance
such as Sr and Ra, bacteria. Coli form and other carcinogen existed in the water as well. It is the
ideal water supply equipment in various fields.
Precision filters
This machine is made of stainless steel as a small tank which contains precision filter membrane.
It only allows un- treated water to go through the membrane, and does not allow any liquid go
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through other parts, so it can filter the un- treated water. The filter precision is from 0.1µm-60
µm.
Hollow Fibre Filter
Hollow fibre filter is of membranes widely used in late decades for separation, condensation and
filtration.
The equipment employs asymmetric semi permeable membrane which is of polymer and out of
special technique to prevent polymers such as protein, nucleic acid and polysaccharide or colloid
particles from entering the membrane, while pure water penetrates, thus fulfilling the separation
and purification.
Sun ray sterilizer
Sun ray sterilizer is an enclosed unit consist of the sterilizing tube, the electric unit and the body.
The sterilizing tube enclosed with pressure and of stainless steel, which has good reflection of
ultra violet ray and it conform to food hygiene rules. Inside the tube are the ultra violet light and
the quart glass tube. There are entry and exit on the sterilizing tube with stainless connects, seals
and flanges.
The electrical unit adapt to the requirement of ultra violet sterilizing. There is alarm, indicating
light and voltage instrument in the unit. In some cases, two ultra violet lights can be applied for
more volume treatment of water.
The body is to protect the ultra violet light and the quartz glass tube from the damage of
crashing.
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QHW Ozonizer
Ozone sterilizer is a special devise for ozone generating, ozone sterilizer is a combined type air
purified; step up transformer, voltage regulator, and electric controller that produce ozone (4.5-
5g/h) the allotrope of oxygen whose molecular formula is O3. Ozone is a kind of oxidant in the
purified water. It has a special effect on degradation of the contaminating in the purified water
that passes through it.
4.4 Responsibility
The quality manager has an overall responsibility for ensuring this responsibility
4.5 Definition
-
 Critical control point monitoring format
 Production and technical work instruction
 Log book
 Cleaning and sanitation sop
 Back wash record forms
Procedures
Quality manager The quality manager is responsible to prepare a treated

water requirement plan taking the annual production plan
into consideration.
Should present the man power requirement plan to HR
department.
Is responsible to plan the necessary treatment material
requirement and present to procurement.
Shift chemist Is responsible to monitor water treatment operations
Should assign the proper man power in each unit
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operation
Should keep the necessary water consumption records
and report.
Water treatment operators Is responsible to operate the water treatment plant and
produce quality approved water
Is responsible to keep the minimum loss during
production.
Is responsible to put every necessary data on the log book
or format.
5. Cleaning, sanitation and personal hygiene
5.1 Purpose
The purpose of this manual is to have an effective cleaning, sanitation and personal hygiene
program to conduct smooth production operation that is free of contamination in purified
mineral water bottling plant.
5.2 Scope
The scope of these manual covers all cleaning and sanitation operation of the purified mineral
water bottling plant.
5.3 Theory
Production personnel’s shall at all times ensure a high level of hygiene while working on
production machines to avoid contamination using the cleaning and sanitation and personal
hygiene standard operating procedures.
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5.4 Responsibility
The quality manager an overall responsibility to lead, direct and control of the cleaning,
sanitation and personal hygiene operation of the plant.
5.5 Definition
- PPE is personal protective equipment
 Cleaning and sanitation standard operating procedure

 Personal hygiene standard operating procedures
 Processing plant cleaning and sanitation follow up forms
 Personal hygiene follow up forms
 Stores hygiene control forms
 Purchase requisition.
 Production and technique work instruction.
 Log books
Procedures
Quality Manager The quality manager is responsible to prepare the

sanitation plan as part of the production plan
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Should select and prepare a list of sanitation chemical
and PPE present to procurement department
Should monitor the sanitation operation against the
plan
Shift chemist Should request and store the right sanitation material
based on the planned requirement.
Should assign the proper manpower in each
programmed sanitation operation with the necessary
cleaning and sanitation material
Should follow and control the personal hygiene of each
worker PPE as per the personal hygiene standard
operating procedure.
6. Cap and pre form injection machine
6.1 Purpose
The purpose of this manual is to have an effective injection operation of cap and pre form
production.
6.2 Scope
The scope of these manual covers all injection operations of the natural mineral water bottling
plant.
6.3 Theory
The cap injection machine using a mixed HDP and master batch will form a cap which need
further processing to fold the edge on a edge folding machine, the folded cap will further be
processed on slitting machine to slit the cap that easily unscrew during consumption of the
product. If the bottling plant produces a carbonated beverage the cap need to have a seal inside
the cap that can be prepared on cap liner dropping machine.
A pre form machine is used to mix proportionally text pet and heat to produce a pre form of
different size 0.5lt, 1lt and 1.5lt which is the raw material for blow moulding. The blow
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moulding receiving a pre form via a conveyor and heat blows and mould out the different size
bottles size 0.5lt, 1lt and 1.5lt of plastic bottle
6.4 Responsibility
The production manager has an overall responsibility to lead, direct and control of all injection
operation of the plant.
6.5 Definition
HDP- High density polyethylene

 Production and technique work instructions
 Purchase order
 Product monitoring format
 Log book
 Performance record format
 Intermediate product transferring and receiving format.
Procedures
Production Manager The production manager is responsible to plan the cap

and injection quantity requirement based on the
company plan or market requirement.
Should quantity the raw material requirement
equivalent to the required amount of caps and pre form
and present to procurement.
Should monitor the injection operation against the
plan
Production supervisor Should request and store the raw material based on
the planned requirement.
Should assign the proper manpower and control in
each programmed injection operation.
Should monitor the injection operation and report the
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status.
Injection operators/helpers Is responsible to operate the injection machine and
produce the respective caps and pre forms at the right
quality
production
Is responsible to put every necessary data on the log
book or format.
7. Rinsing, filling and cap machine
7.1 Purpose
The purpose of this manual is to have an effective plastic bottle rinsing, filling and capping
operation in processing plant.
7.2 Scope
The scope of these manual covers all rinsing, filling and capping operations of the natural
purified water bottling plant.
7.3 Theory
The machine is mainly used for filling carbonated drink. It combines rinsing and filling and
capping as one automatic body suitable for pet or other plastic bottles. The iso-pressure (iso-
barometric) filling technology is adapted enabling it to fill more efficiently and more stably with
more output than the machine of the same level from others.
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Besides using photo-electric detectors to detect the running of every important sub- process, it
employs PLC from OMRON for automatic control of the whole process and new type air
channel for bottle- loading featuring speediness and damage free of bottles. The handing over of
bottles between two linking structures is fulfilled by applying clamping bottle neck method. For
bottle of different shape only a few parts need to be changed and the substituting is simple,
which shows the machine is of good adaptability
7.4 Responsibility
Production manager has an overall responsibility to control of all rinsing, filling and capping
7.5 Definition

 Intermediate product receiving and transferring voucher

 Performance record format
 Log book
 Production and technique work instructions
Procedures
Production Manager The production manager is responsible to plan and

communicate the type of bottles and quantity
requirement based on the company plan or market
requirement.
Should monitor the filling operation against the plan
and report to the top management.
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Production supervisor Should request and store the plastic bottles and caps
based on the planned requirement.
Should approve the quality requirement.
Should assign the proper manpower in each filling
operations.
production
book or format.
Filling operators Is responsible to all the filling operation of caps and
pre forms production.
production
book or format.
8. Inspection line and date coding
8.1 Purpose
The purpose of this manual is to have effective inspection operations to avoid defective bottles
and coding of all defect free bottled purified water.
8.2 Scope
The scope of these manual covers all quality inspection operations and coding of the natural
8.3 Theory
INSPECTION
The bottle from filler is inspected for possible defects like over and under filled, damaged plastic
bottles and any visible dirt or foreign matter inside the bottle by trained female inspectors who
inspects exhaustively assigned by rotation scheme of 30 minute interval.
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PRINTER
The product as one of the food safety requirement should have a traceability data back to the
specific raw material and process and a printer is used to code each bottles with the date of
manufacturing and the estimate expiry date.
8.4 Responsibility
Production supervisor have an overall responsibility to lead, direct and control of all inspection
and coding operation of the plant.
8.5 Definition
-
 Bottle inspection follow up format
Procedures
Production supervisor Is responsible to control all the inspection operations

Inspection workers Are responsible to inspect and avoid all defective
bottles.
Date coding technician Is responsible to operate the labeling and group
packing
production
9. Labeling and group packing
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9.1 Purpose
The purpose of this manual is to have an effective labeling and group packing operations and
produce properly labeled group packed bottled purified water.
9.2 Scope
The scope of these manual covers all labeling and group packing operations of the natural
9.3 Theory
9.4 Responsibility
Production supervisor have an overall responsibility to lead, direct and control of all
inspection operation of the plant.
9.5 Definition
-
 Performance report format
 Log book
 Technical and production work instruction
 Store requisition.
Procedures
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Production manager The production manager is responsible to plan and

communicate label and poly bag quantity requirement
based on the company plan or market requirement.
Should monitor labeling and group packing operation

against the plan and report to the top management.
Production supervisor Is responsible to control all labeling and group
packing operations
operators Is responsible to operate the labeling and group
packing machine.
production
book or format.
10. Delivery
10.1 Purpose
The purpose of this manual is to have an effective product delivery in bottled mineral water.
10.2 Scope
The scope of these manual covers all product delivery operations of the natural mineral water
bottling plant.
10.3 Theory
10.4 Responsibility
Production supervisor have an overall responsibility to lead, direct and control of all delivery
10.5 Definition
-
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 Final product transfer voucher
 Log book
 Store requisition.
 Product quality approval format.
 Product summery format.
 Nonconforming product registration logbook
 Rework report
Procedures
Production manager The production manager is responsible to plan the

delivery schedule as part of the production plan.
Production supervisor Is responsible to deliver all quality approved product
to store.

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GOLD WATER BOTTLING AND

NON-ALCOHOLIC BEVERAGE FACTORY

July, 06, 2020

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

ISSUE HISTORY.........................................................................................Error! Bookmark not defined.

1. Abbreviations and symbols...............................................................................................................5

2.6 Related document............................................................................................................................8

3.6 Related document............................................................................................................................9

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

4.6 Related document..........................................................................................................................13

5. Cleaning, sanitation and personal hygiene........................................................................................14

5.6 Related document..........................................................................................................................15

6. Cap and pre form injection machine..................................................................................................16

6.6 Related document..........................................................................................................................16

7. Rinsing, filling and cap machine.........................................................................................................18

7.6 Related document..........................................................................................................................19

8. Inspection line and date coding..........................................................................................................20

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

8.6 Related document..........................................................................................................................21

9. Labeling and group packing...............................................................................................................21

9.6 Related document..........................................................................................................................22

10.6 Related document........................................................................................................................23

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

1. Abbreviations and symbols

HDPE: High Density Polyethylene

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

Action criterion (3.2)

Control Measure (3.8)

Critical control point - CCP (3.11)

Critical limit (3.12)

Food safety hazard (3.22)

Operational prerequisite programme - OPRP (3.31)

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

Prerequisite program - PRP (3.35)

Significant food safety hazard (3.40)

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

2.6 Related document

Production Manager The production manager is responsible to plan

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

Direct materials to be received and/or stored

 Natural mineral water

 Pet resin/ poly ester/

HDP AND PET RESIN Deliveries

Production Manager The production manager is responsible to present the

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

1. Total Dissolved Solids

RAW WATER STORAGE TANK

SVS silica sand filter

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

Hollow Fibre Filter

Sun ray sterilizer

Quality manager The quality manager is responsible to prepare a treated

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

5. Cleaning, sanitation and personal hygiene

Doc ID: GW/PM/PD/001 Title: Production manual Owner: PM

- PPE is personal protective equipment

3.6 Related document

 Cleaning and sanitation standard operating procedure