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INTERNSHIP REPORT
ON

PREPRATION OF DIFFERENT FOOD AND BEVERAGES PRODUCTS

AT

TOPS FOOD & BEVERAGES, RAWALPINDI

BY

Ailia Batool
19-ARID-4484

SESSION

2019-2023

The internship report submitted 15 March, 2023 in fulfillment of the requirement of the degree
of

B.Sc. (Hons.) Agriculture

IN
FOOD SCIENCE AND TECHNOLOGY

INSTITUTE OF FOOD AND NUTRITIONAL SCIENCES

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PIR MEHR ALI SHAH ARID AGRICULTURE

UNIVERSITY
RAWALPIN
ACKNOWLEDGMENT

The internship opportunity I had with TOPS FOOD & BEVERAGES, RAWALPINDI was a
great chance for learning and professional development. Therefore, I consider myself as a very
lucky individual as I was provided with an opportunity to be a part of it.
Bearing in mind previous I am using this opportunity to express my deepest gratitude
and special thanks to the Sir. Saif-Ullah (Production Managers) who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path
and allowing me to carry out my internship at their esteemed organization and extending during
the training.
It is my radiant sentiment to place on record my best regards, deepest sense of
gratitude to Sir Amjad (QC&S) and Sir Akbar of Top’s Food & Beverages Rawalpindi, for
their indispensable cooperation and provided me facilities to conduct internship in their
departments.
I want to pay my special thanks to my Teacher and Supervisor Dr. Asif Ahmed for
their dynamic supervision, their careful and precious guidance which were extremely valuable
for my study both theoretically and practically.
I perceive as this opportunity as a big milestone in my career development. I will strive
to use gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives
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\
INTERNSHIP OVERVIEW
Being an intern at the Quality Control Department at TOPS FOOD AND BEVERAGE
INDUSTRY RAWALPINDI, I had taken a number of operations and managed the
product quality along with team and my quality control officer Sir Amjad. Initially, I had
given the responsibilities of a Quality Control Officer. Hence, I worked on the production
lines of 125ml, 200ml, 250ml and 1 Liter Tetra Pak products along with the 320ml,
500ml, 1 Liter, 2 Liter PET product lines. I learnt a lot regarding quality control and
quality assurance of the beverage products. We controlled the quality of products by
checking the finished products and identifying the flaws present. We also assured the
quality of the products by identifying different loopholes present in the line and thus
helped in maintaining the quality of products. We prepared the daily quality reports of the
production lines. We checked the quality standards of the batch that is being prepared,
performed sensory evaluation and approved the batch for final production. We were
responsible for maintaining all the quality standards of a batch of beverage product. We
also checked the first few samples from each batch and checked their quality standards
and reported to my officials in case of any incompliance.
We also maintained the daily Cleaning and Sanitation records and checked every nook
and corner of the plant.

INTERNSHIP
OVERVIEW
We also performed different lab tests which include Brix test with refractometer, Total
Acidity through titration, pH tests through pH Meter and pH indicator strips. We checked
these standards of the Pulp or Concentrate that is about to be used for production of
beverage products. We also checked the batch and approved it before final production. In
nutshell, through this internship, I became familiar with quality control and quality
assurance standards and protocols of beverage industry. Now, I can efficiently work in a
beverage industry and can maintain the quality of fruit drinks and nectars.
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TABLE OF CONTENTS
Chapter 1: Introduction
1.1. Introduction and History to Tops Food and Beverages
1.2. Our values
1.3. Certifications
1.4. Product Range
1.5. Competitors
Chapter 2: Departments
2.1. Administration department
2.2. Procurement department
2.3. Quality Control department
2.4. Production department
Chapter 3: Ingredients and Functionality
3.1 Functions of ingredients
Chapter 4: Nutritional value and ingredients of fruits and flavored drink
4.1 Fruit drinks
4.2 Flavored drinks
4.3 Nectar drinks
Chapter 5: Juice Production
5.1. Flow Chart
5.2. Juice production processing
5.3. Sugar syrup preparation
5.4. Blending
5.5. Homogenization
5.6. Pasteurization
5.7 Filling
5.8. Straw Application
5.9. Packing
5.10 Data Coding
5.11 Final Good Storage
5.12. Transportation
Chapter 6: Packaging Material
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6.1. Packaging material

6.2. Sterilization of Tetra Pak Cartons
6.3. HACCP Checking During Aseptic Filling
Chapter 7: Quality Testing Methods
7.1. Titration
7.2. Determination of So2
7.3. Determination of Brix
7.4. Purity of H2O2
7.5. Determination of PH
7.6. Determination of TDS
7.7. Appearance, Odor and Taste of Juices
7.8. Water Hardness
7.9. Analysis of CIP Solution
7.10. Acidity of Juice
7.11. Arsenic Test
7.12. Determination of chloride in water
7.13. Determination of nitrate
7.14. Determination of Magnesium
Chapter 8: Dispatch and Quality Assurance
Chapter 9: Shelf Life and Product Labelling
9.1. Shelf Life Steady
9.2. Product labelling/Nutrition
Chapter 10 Our Duties
Chapter 11 Swot Analysis
Strength
Weakness
Opportunities
Threats
Conclusions
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CHAPTER NO: 01

1.1. INTRODUCTION & HISTORY

TOPS FOOD AND BEVERAGE:

Tops Food & Beverages, a division of Murree brewery company limited, processes fruits and
markets fruit juices and allied food products. Established in 1969, the division has, nowadays,
two manufacturing units located in Rawalpindi and Hattar (KPK), respectively.

Tops Food Rawalpindi unit is producing Tetra Pak juices and is well equipped with state of the
art Tetra Brick Aseptic machines. Currently six different juices are being producing in this
branch, two of which are fruit drinks and remaining four are flavored drinks. Fruits drinks are
Mango juice and Guava juice and flavored drinks includes Apple juice, Orange Mango mixed
flavored drink Peach juice.

Both plants of Tops company are Halal, ISO 9001, HACCP, ISO 22000, certified from the world
recognized certification bodies.
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HISTORY:
Tops Food and Beverages was established in 1969. It processes fruits and markets fruit juices
and allied food products. Two manufacturing units are located in Rawalpindi and Hattar (KPK).
A Tetra Pak packaging facility was added in 2001. The Hattar plant was installed in 1992. Tops
Food Rawalpindi unit is producing Tetra Pak juices and is well equipped with state of the art
Tetra Brick Aseptic machines.
Tops Hattar plant is producing juice, drinks, Jams, Vinegars, Ketchup, squashes. Both plants are
Halal, ISO9001, HACCP and ISO 22000 certified from world’s renowned certification bodies.

1.2. OUR VALUES:

Tops Food and Beverage has a culture that welcomes and initiate change, innovation which leads
to the environment where the employees are empowered and engaged having high morale,
motivation and productivity for strong team work and perfection in their work to produce loyal
customers. To raise business constantly and uncompromisingly maintaining quality controls and
leadership through encouraging correlation with the consumer to entire customer's satisfaction
and to carry on repetitively. Upgrading by adopting those business practices which attach worth
for its consumers, workforce and investors. We at Tops Foods and Beverage never forget what
we are here for.
Following are our core values:

• Accountability and Balance- Responsibility of our actions that influence the lives of our
customers and fellow workers and maintaining Healthy life and work balance for workers

• Collaboration-Collaborating within and outside the company to give the best

• Commitment-Commitment to roll great product, service and other initiatives that impact
lives both within and outside the organization

• Community- A sense of responsibility and contribution to society that define

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existence of existence

• Consistency- To be consistent in offering the best for wonderful experience

• Diversity- Respecting the diversity and giving the best of the composition
• Efficiency- Being efficient and effective in our approach to give best solution each time
• Empowerment- Empowering the employees to take initiative and give the best
• Fun- Having fun and celebrating small successes in our journey to achieve big
• Innovation- To come out with new creative ideas that have the potential to change
the world

• Integrity-To act with honesty and integrity without compromising the truth
• Leadership- The courage to lead from front and shape future
• Ownership- Taking ownership of the company and customer success
• Passion-Putting the heart and mind in the work to get the best
• Quality-Giving the best and unmatched results for all round satisfaction
• Respect-Giving due respect to self and others and maintain the environment of
team work and growth

1.3. CERTIFICATIONS:
Pure food Foods Products are made with care and marked with our quality seal of recognition.
These internationally recognized tests are used to check microbiological contamination and
adequacy of nutrients. All processes, from preparation to packaging, are undertaken employing
state-of-the-art technology and equipment. Therefore, we take great pride in the fact that Tops
Food & Beverage Products is the company in Pakistan that has the following certifications of
quality and prestige:
PUNJAB FOOD AUTHORITY
The Main theme of this Authority is to ensure food safety from farm to fork that the pure,
healthy and nutritious food reach the consumers. The authority started work for the
implementation of the quality standards according to the Punjab Food Authority (PFA) Act 2011.
Authority working for the implementation of Punjab pure Food Rules to ensure the food safety
from farm to fork.
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HACCP Certification:
The Hazard Analysis and Critical Control Points (HACCP) system is a logical, scientific
approach to controlling hazards in meat production. HACCP is a preventive system assuring the
safe production of food products. The application of HACCP is based on technical and scientific
principles that assure food safety. An ideal application would include all processes from the farm
to the table.
The principle of HACCP can be applied to production, meat slaughter and processing, shipping
and distribution, food service and in home preparation.

Pakistan Standard and Quality Control Authority PSQCA

The main function of the Authority is to foster and promote standards and conformity assessment
as a means of advancing the national economy, promoting industrial efficiency and development,
ensuring the health and safety of the public, protecting the consumers. Facilitating domestic and
international trade and furthering international co-operation relation to Standards and conformity
assessment in the interest of consumers.

Sindh Food Authority (SFA):

SFA is responsible for regulating food safety and hygiene standards in the Sindh
province of Pakistan.
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Khyber Pakhtunkhwa Food Safety and Halal Food Authority:

This regulatory body is responsible for ensuring food safety and hygiene standards in the Khyber
Pakhtunkhwa province of Pakistan.
Ministry of National Food Security and Research:
This ministry is responsible for formulating policies related to food security and research, as well
as overseeing food safety and quality standards at the national level.

Drug Regulatory Authority of Pakistan (DRAP): DRAP is responsible

for regulating the quality and safety of food additives, food supplements, and other food-related
products in Pakistan.

1.4. PRODUCT RANGE:

NECTOR/ JUICE 200ML

Mango Nectar Orange Nectar Apple Nectar

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TOPS TETRAPACK DRINK (250 ML)

Apple Apple Banana Guava Peach

Orange Mango Kalmi Mango Juice Drink Pulpy Apple Drink

1.5. COMPETITORS:
NESTLE
NESTLÉ FRUITA VITALS is a brand that inspires the world to be more positive and
encourages people to celebrate the positivity around them because every day might not be good
but there is something good in every day. NESTLÉ FRUITA VITALS Premium range is
currently available in Chaunsa, Red Grape, Apple, Kinnow, Pineapple, Guava, and Peach. While
NESTLÉ FRUITA VITALS Super Premium range is available in Red Anaar that offers the
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perfect blend of super fruit. Striving to bring you the best of nature, NESTLÉ FRUITA VITALS
proudly announces the launch of its Exotic Mixes Range through two new flavors - Mint
Margarita & Pina Colada. Beat the heat this summer and refresh yourself with our NEW flavors
which bring to you the perfect beach feels.

JUICE PACK
Since October 1962, Juice Pack Limited is being considered one of the leading and larger
concerns in the fruit and beverage industry of Pakistan. At inception fruit and vegetable
processing unit together with a fruit juice bottling plant were targeted to produce quality products
symbolically known as "Juice Pack". In its golden era in 1971, the company equity base was
broaden to raise additional funds for plant of filling vegetables, fruits and fruit juices in cans to
consolidate its market share.

SHEZAN
Since its inception in 1964, Shezan has evolved into a top-notch, internationally acclaimed food
brand that is set apart due to the impeccable quality. With our wide range of products made with
the freshest fruits and vegetables from our orchards, Shezan aims at providing you the diverse
flavors of Pakistan.

SIX B
Six b food industries pride itself as one of the leading manufacturers in the category of
confectionery and beverages. It was started in 1985.The company is well equipped with the latest
equipment’s and techniques.
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CHAPTER NO: 02
DEPARTMENTS:
The departments in the tops food and beverage are:
2.1. ADMINISTRATION DEPARTMENT
This department arranges all plans and connections between other departments and also perform
duties of finance and human resource department this department actually a combination of
human resource and finance department.

2.2. PROCUREMENT DEPARTMENT

This Department arranges raw material for processing through efficient collection system. Raw
material collected from different areas of Punjab, Sindh province for processing purposes. This
department have the great responsibility to collect the accurate raw material according to need
and of good quality.

2.3. QUALITY CONTROL DEPARTMENT

This Department includes main lab

Quality Manager

Assistant Quality Manager

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Quality
Microbiologist Quality Assurance
control
Officer
Executive

Quality control
Officer

There is a well-established system of laboratories o r the analytical evaluation of the different

Q u ali ty C o n t ro l
materials used in Tops Food and beverage. There are tw o d iv is i o n s
Inspector
•Quality control (QC)
• Quality System (QS)
Quality Control (QC)
The main responsibilities of QC are;
• Raw material checking
• In processing checking
• Complaint handling
• Release of final product
Quality System (QS)
The main responsibilities of QS are
• Quality system implementation and Audit like HACCP, ISO and GLP Etc
• Various type of staff Training
2.4. PRODUCTION DEPARTMENT:
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The Production department is headed by production manager having overall

responsibility of production, according to quality parameters. Hierarchy of this
department is following:
• Production Manager
• Shift in charge
• Process Officer (Production supervisor)
• Packaging section (Packing Supervisor)
• Warehouse (Shipping Supervisor)
This department receive daily production plan and execute.

CHAPTER N0: 3
3.1. RAW MATERIAL & INGREDIENTS
Raw material required for manufacturing fruit juice are fruit pulp, citric acid, food color, sugar,
preservatives and fruit flavors. Although, juice manufacturers use molasses to thicken the juice,
this is not a good practice and therefore should be avoided. All raw materials are easily available
in the local market; however, fruit pulp is considered to be the principal component of the high-
quality fruit juice, therefore, its continuous and within the required quantity availability will need
some advance planning

INGREDIENTS
 CMC
 VITAMIN C
 CITRIC ACID
 SODIUM CITRATE
 SODIUM BENZOATE
 SUGAR
 WATER
 PULP
 FLAVOR

3.2. FUNCTIONS OF INGREDIENTS:

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CMC
• Major constituent of Juice
• CMC works as the thickening, emulsifying, suspending, stabilizing, shaping, filming, bulking,
anticorrosion, retaining freshness, acid resisting and health protecting agent
• CMC can be placed the application of guar gum, gelatin, agar, sodium alginate and pectin.
• It is widely used in modern food industry such as frozen food, solid drinks, jam, lactic acid
drinks and the bakery products also
• In liquid beverages CMC used in fruit tease, fruit drinks and vegetable juice to suspend fruit
pulp and for the bright colors and to improve their taste

Vitamin C
Vitamin C is used in juice as an antioxidant agent. Vitamin C helps to grow and repair tissue
throughout your body, counter free radicals which caused cell damage and fight the negative
effects of toxins. Vitamin C is not naturally occurring supplement nor it is stored in the body so
must continually replenished through consumption why food are supplements all fruited and
vegetables contains Vitamin C.

Citric Acid
The main functions of the citric acid in juice are given as under.
• Act as flavor adjacent
• Act as taste improver
• Act as PH controller
• Act as chelating agent to improve the actions of antioxidants and prevent of spoilage of juice.
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Sodium Citrate
The main functions of the Sodium Citrate in juice are given as under.
• Act as flavor adjacent
• Act as taste improver
• Act as PH controller

• Act as chelating agent to improve the actions of antioxidants and prevent of spoilage of
juice
• It is also used as emulsifying agent
• It works as buffer solution
• Works as food additive
Sodium Benzoate
The main functions of the Sodium Benzoate in juice are given as under.
• Act as preservatives in juices
• Used in acid juices then natural juices
• It reduces the bacterial activity in juices
Sugar
The main functions of the Sodium Benzoate in juice are given as under.
• Act as preservatives in juices
• Used in acid juices then natural juices
• It reduces the bacterial activity in juices
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Sugar
The main functions of the Sugar in juice are given as under.
• Act as preservative in juices
• Provide sweetness the juices
• To work with the sweetener helps to maintain the sweetness of juice
Water
• Main function is hydration of dry materials
• Acts as a solvent
• Controls dough temp
• Controls dough consistency
• Imparts softness to final product
Pulp
A juice cannot be directly produced from fresh fruits throughout the year because of dwindling
supply and seasonal variations which subjects to unavailability of fruits in certain periods of time
in a year. For this Purpose, the Fruits with high Fiber content are passed through a series of steps
in order to extract their pulp and the Juices extracts of the fruits which naturally produces the
Juice are concentrated to not only make a readily available supply of juices throughout the year
but it also saves the valuable space of the Cold stores and facilitates the production of Beverages.
FLAVOR
They are designed to eliminate the perception of one or more undesirable attributes. Functional
flavors are often used in beverages containing high-intensity sweeteners. Flavor additives are
responsible for much of a drink's sensory profile. They provide consumers the opportunity to
enjoy unique flavors they may not otherwise be able to experience in their original form, and
they help beverage companies deliver consistent, high-quality experiences with their products.
FOOD COLOR’s
A color additive, as defined by regulation, is any dye, pigment, or other substance that can impart
color to a food. Color additives are important components of many products, making them
attractive, appealing, appetizing, and informative. For food to remain attractive to consumers,
food manufacturers add natural or artificial colors to return or enhance some of the color
consumers would expect from food (ever thought about cheese puff snacks not being yellow or
orange?). Vegetable and fruit juices are good examples.
H2O2
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Addition of hydrogen peroxide (H2O2) is a method commonly used to trigger cellular oxidative
stress. However, the doses used (often hundreds of micro molar) are disproportionally high with
regard to physiological oxygen concentration (low micro molar). Hydrogen peroxide-induced
oxidation of ascorbic acid was found to be catalyzed by several fruit juices.

CHAPTER NO: 4
NUTRITIVE VALUE AND INGREDIENTS OF FRUIT AND FLAVORED
DRINK

4.1. NUTRITIONAL VALUE AND INGREDIENTS OF FRUIT DRINK

GUAVA FRUIT DRINK
Ingredients
Guava Pulp 10%, Sugar, Citric Acid (E-330), Synthetic Guava Flavor,
Preservative (Sodium Benzoate E-211) Permitted Food Colors (Ponceau 4R
Raspberry Red W124c), Stabilizer (CMC E-466)
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Nutritional Table (per 100 ml)

Calories (100) 40 kcal
Total Carbohydrates 10.6 g
Dietary Fiber 0.08 g
Vitamin C 8 mg
Percent daily values are based on a 2000 Calories diet

PEACE FRUIT DRINK

Ingredients
Sugar, Peach Pulp 10%, Sugar, Citric Acid (E-330), Ascorbic Acid (E-300), Synthetic Peach
Flavor, Preservative (Sodium Benzoate E-211) Permitted Food Colors (Lime Juice Yellow E-
102 & Orange Red 52 E-151, E-122, E-110), Stabilizer (CMC E-466)

Nutritional Table (per 100 ml)

Calories 40 kcal
Total Carbohydrates 10 g
Dietary Fiber 0.0 g
Vitamin C 0.0 g

Percent daily values are based on a 2000 Calories diet

MANGO FRUIT DRINK:

Ingredients
Fruit Content 8%, Sugar, Citric Acid (E-330), Synthetic Mango Flavor, Preservative (Sodium
Benzoate E-211), Permitted Food Colors (Tartrazine Lime Juice Yellow E 102 & Beta Carotene,
Orange Red E 160a), Stabilizer (CMC E-466)

Nutritional Table (per 100 ml)

Calories 40 kcal

Total Carbohydrates 10 g
Dietary Fiber 0.0 g

Vitamin C 0.0 g

Percent daily values are based on a 2000 Calories diet

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4.2. NUTRITIONAL VALUE AND INGREDIENTS OF FLAVORED DRINK

APPLE FLAVORED DRINK

Ingredients
Sugar, Citric Acid (E-330), Artificial Apple Flavor, Preservative (Sodium Benzoate E-211),
Permitted Food Colors (Caramel Color E 150D), Stabilizer (CMC E-466).

Nutritional Table (per 100 ml)

Calories 40 kcal
Total Carbohydrates 10 g
Dietary Fiber 0.0 g
Vitamin C 0.0 g

Percent daily values are based on a 2000 Calories diet

APPLE BANANA FLAVORED DRINK

Ingredients
Sugar, Citric Acid (E-330), Artificial Apple & Banana Flavor, Preservative (Sodium Benzoate E-
211), Clouding Agent, Stabilizer (CMC E-466)

Nutritional Table (per 100 ml)

Energy 112Kcal % Daily values 44.8

Total Fat 0.0g 0.0% 0g
Sodium 20mg 0.8%
Total Carbohydrates 10.2% 10.2 g

Of which Sugars 25.5g 10.2g

Dietary Fiber 0.0g 0.0% 0g

Protein 0.0g 0.0% 0g

Percent daily values are based on a 2000 Calories diet

ORANGE MANGO MIXED FLAVORED DRINK

Ingredients
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Sugar, Citric Acid (E-330), Artificial Orange & Mango Flavor, Preservative (Sodium Benzoate
E-211), Permitted Food Colors (Lime Orange Mango Shade E-102 & E-110), Stabilizer
(CMC E-466)

Nutritional Table (per 100 ml)

Energy 112Kcal % Daily values 44.8

Total Fat 0.0g 0.0% 0g
Sodium 20mg 0.8%
Total Carbohydrates 10.2% 10.2 g

Of which Sugars 25.5g 10.2g

Dietary Fiber 0.0g 0.0% 0g

Protein 0.0g 0.0% 0g

Percent daily values are based on a 2000 Calories diet

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4.3. NUTRITIVE VALUE AND INGREDIENTS OF NECTAR

DRINK Natural Flavored Mango Nectar Drink
Ingredients
Water, Mango Pulp (Fruit Content 25%), Sugar, Citric Acid (E-330), Carboxymethyl
Cellulose, Natural Mango Flavor, Preservative (Potassium Sorbate, Ascorbic Acid), Permitted
Food Color (Beta-Carotene)
Nutritional Table (per 100 ml)
Calories 135 Kcal
Total Fat 0g 0%
Sodium 25mg 1%
Total Carbohydrates 33.7g 12%
Total Sugars 29g
10.2g
Included 25g Added Sugars 50%
Vitamin D 1mcg 0g
Iron 0.6mg 4%
Proteinin 0g
Percent daily values are based on a 2000 Calories diet
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CHAPTER N0: 05
JUICE PRODUCTION

5.1. JUICE PRODUCTION PROCESS AND FLOW CHART

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5.2. JUICE PRODUCTION PROCESSING

5.2.1. PROCUREMENT OF RAW MATERIAL:

The first step involved in the production of a product is the procurement of goods and raw
materials that combine and give the desired end product. For that purpose, suppliers that have
good track record are contacted, and once the supplier evaluation is done, the raw material before
delivery comes in the form of a sample.
The quality team checks that sample for its suitability in accordance with the need of the product.
This may involve performing some particular quality tests on the sample and ensuring that it
fulfills the set parameters. Once the sample is approved the raw material is ordered in bulk.

5.2.2. RECEPTION OF RAW MATERIAL:

Once the raw material arrives at the factory, initially two departments are brought into action, the
security team and the purchase office. They arrange for the transit of the goods and before
unloading the quality of the raw material is checked by the quality control personnel.
This checking first involves the physical inspection of the raw material. Then a random sample is
taken from the lot and checked for quality parameters, it dictates that whether the goods are to be
quarantined or sent back (if the quality tests are not cleared) or unloaded.

5.2.3. STORAGE OF RAW MATERIAL:

This is an important step in the production of the

product as the raw materials are ordered in bulk
and they may be used for longer periods so their
safety and proper storage is very much required.
Store’s conditions are set at optimum for long
storage of the raw material. Raw materials that
are stored include Sugar, other artificial
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sweeteners, stabilizers, emulsifiers, fruit pulp, flavors, colors, concentrated acids and chemicals
for use in the factory.

Concentrated acids and chemicals are stored separately in Cold storage room which are going to
be used in juice production. Specific conditions of ventilation, temperature, humidity etc. are
maintained.

5.2.4. RAW MATERIAL AT PRODUCTION AREA:

From the chemical and goods store all the required chemicals per requirement of the batch are
brought to the production area. These materials are temporarily stored in the dispensing room for
immediate use as required. Weighing of ingredients is done in the dispensing room.

5.3. SUGAR SYRUP PREPARATION:

Sugar is an important ingredient in the tetra pack juice which gives sweetness to the juice. It is
added in the juice mixture in the form of syrup. Syrup is prepared in the syrup tank having
capacity of thousands of liters.
Water is added in the common sugar and then steam is introduced which melts the sugar and
prepares a hot mixture of sugar and water. A common batch of syrup usually contains 500 Kg of
Sugar which is added with 200 L of water.
Continuous agitation is ensured Temperature in the syrup tank is maintained at about 200 to
250oC.During this syrup production step some other ingredients of the juice also have to be
added in the syrup. These include Sodium Benzoate and Carboxy Methyl Cellulose (CMC).

5.3.1. RECIPE FOR JUICE FORMATION:

In the Top factory there are two blending tanks of different capacities, large ones with a capacity
of 9000 L and the smaller ones with 3000 L capacity. Water is major ingredient in the juice
production.
 Tank is filled with water at the level of about 8000 liters and chemical ingredients are
added as per the set formulation for different products. Ingredients include potassium
 P a g e | 27

metabisulphite (KMS), sucralose, fruit pulp, sodium cyclamate, citric acid, artificial
flavors and colors. Continuous agitation is also ensured here. After addition of all the
ingredients, sugar syrup is added in the juice mixture present in the blending tank.
Sugar syrup is added up to the required Brix for different products. The blender
continuously checks for the o Brix of the juice with the help of a refractometer and stops
the addition of sugar syrup once the required o Brix is obtained. Then the juice sample is
sent to the laboratory for quality checking. Different tests are performed on the juice
sample to ensure that all the ingredients are added in set proportion and the product will
perform well and stay safe during its expected shelf life period.

5.4. BLENDING:

The juice mixture is allowed to blend in the blending tank, a complete batch is blended at the
room temperature to ensure the mixing of all the ingredients. Normally a blending of 2 hours is
performed.

5.5.1. HOMOGENIZATION:

The juices in which fruit pulp is added have to be homogenized in order to ensure the even
distribution of fruit particles. Usually the mango juice and others in which pulp is added are
homogenized. Juices without the pulp addition need not to be homogenized.
Tetra Pak homogenizer is installed within the pasteurizing plant. It contains a tank and pumps
operating with the help of motors. These pumps are three in number and completely mix the
juice and the pulp. Pressure of about 100 to 150 psi is maintained in the homogenizer.
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5.5.2. PASTEURIZATION:
Tetra Aseptic pasteurizer is employed for the pasteurization of the juice. It is also a complex
machine having different gauges and valves for temperature and pressure control.
Continuous monitoring is made
necessary here with the help of an
operator that checks for the temperature
and pressure conditions at regular
intervals.
Juice is heated in the plate heat
exchanger with the help of steam to a
temperature of about 98-102oC for
about 30 seconds and then cooled to
about 28oC. Holding time of 30 seconds in very much important for proper pasteurization which
is attained by the flow of juice in the holding tubes for a certain period of time.

5.6. FILLING:

Tetra Pak Juice is always filled aseptically. For this purpose, aseptic filling machines are
employed. There are three filling machines in the factory, one is A3 FLEX which provides the
flexibility to change the Pack size and it is used for the filling of 200 ml and 1-liter packs.
Other two machines are Tetra Brik Aseptic (TBA) and these are used for packing and filling of
250 ml pack. These packing machines are very sophisticated and complex.
 These are prepared before the operation is initiated; it includes placing the packaging
material, setting the MPM strip, checking for the oil and water levels of machine etc.
 Filling is fully automatic and a computer based logical control system operates the
machines on the set instructions.
 Quality is also assured at this step by checking the Hydrogen Peroxide (H2O2)
concentration of the water mixture used to sterilize the packaging material in the aseptic
filling machine. If the concentration of this hydrogen peroxide in the solution is below
the recommended level, it would not be able to properly sterilize the packaging material
which may affect the shelf life of the packaged juice.
 P a g e | 29

 A normal range of 30 – 40 % is maintained. Densitometer is instrument used for this

purpose. Then to ensure that the pack is printed with the date and batch code (an
automatic printer does this operation, it has a sensor that senses the pack passing under it
and accurately prints the date on the prescribed space on the pack, air pressure is also
made to fall on the pack before it passes under the sensor to remove any water droplets
and moisture).

5.7. STRAW APPLICATION:

Tetra Straw Applicator 21 is used to place the straw on the juice pack. This is an automatic
machine and receives the juice packs that come to it on the conveyer belts. Glue is used to attach
the straw on the pack. Glue in the form of pellets is put in the machine where it is melted to a
temperature of around 170°C.The melted glue is allowed to pass through a jet nozzle which
precisely injects the glue on the pack.
 There are two nozzles for glue injection but setting can be done to make only one nozzle
functional. The straw also run in the machine, they are simultaneously cut and fixed on to
the glue point. Water from a small pipe is allowed to fall on the straw immediately after it
is fixed to the pack in order to let the glue cool down. Juice pack then moves on the
conveyer belt to the next unit operation.
 P a g e | 30

5.8. PACKING:
Separate packs are placed in trays of fixed capacity.
The trays are made up of soft card board and are light in
weight. 250 ml packs are placed in somewhat large
trays having capacity of 27 packs and 200 ml packs are
placed in slightly smaller trays having capacity of 24
packs.
Packing is manual and workers are employed in the
hand packing of the juice packs. The packaging in this
fashion is still loose and not safe for transportation and storage so a polyethylene sheet is used to
wrap the trays tightly.
For this purpose, a machine called shrink wrap is utilized. Shrink wrap consists of conveyer belt
that passes through a chamber of high temperature which is usually 180℃.
5.9. DATA CODING
Dates such as production and expiry information, code, batch code and filling machine line,
retail price.
5.10. FINISHED GOODS STORE
The finished and packaged product is now ready for storage. Large storage space is available in
the factory area.
 The company has its other storage outlets in Rawalpindi / Islamabad area and also in
other parts of the country.
 From there the product is purchased by the sellers. All the process in then controlled by
the sales department. After the delivery of the product for sale there are always chances
of some of the product not performing well during its storage, so the product is
exchanged with other batches by the company and in serious cases whole batch has to be
brought back and discarded.
5.11. STORAGE & TRANSPORTATION
Lifter machines drop pack juices in ware house and then supplied to the market.
 P a g e | 31

CHAPTER NO: 06
PACKAGING MATERIAL
PACKAGING MATERIAL:
Tetra Pak cartons are one of the most sustainable packages in existence today. This is because
tetra pack cartons are made predominantly from paper, which comes from wood, renewable
resources that grows back once its cut. The 6-Layer concept is a unique packaging method that is
a true signature of Tetra Pak’s innovative technology. A laminate of six layers consists of high
quality Paperboard, Polyethylene and aluminum. The Paper (70%) provides stiffness, strength
and shape to the package. The Polyethylene (24%) on the innermost layer forms the seals that
make the package liquid-tight. A protective coating on the exterior keeps the package dry.
Aluminum (6%) is the silver material you see on the inside of the aseptic package. The function
and percentage of different layer of Tetra Pak are given below

Polyethylene external layer

➢ 24% (Total percentage
including all layers)
 P a g e | 32

➢ Protect against
outside moisture
Paper board
➢ 70%
➢ Provide stiffness,
strength and sustainability
➢ Maintains distinct
standard shape of the package
Polyethylene adhesive layer
➢ Lamination layer
➢ Creates a strong adhesion
in Aluminium and paper layer
 P a g e | 33

➢ Supports function of
paper by giving it strength.
➢ Prevents moisture to
reach paper
Aluminium foil
➢ 6%
➢ Barrier to Oxygen,
flavour and light
Polyethylene layer
➢ Needed for
lamination process
Internal polyethylene layer
➢ Seals in the liquid.
 P a g e | 34

Polyethylene external layer

➢ 24% (Total percentage
including all layers)
➢ Protect against
outside moisture
Paper board
➢ 70%
➢ Provide stiffness,
strength and sustainability
➢ Maintains distinct
standard shape of the package
Polyethylene adhesive layer
➢ Lamination layer
 P a g e | 35

➢ Creates a strong adhesion

in Aluminium and paper layer
➢ Supports function of
paper by giving it strength.
➢ Prevents moisture to
reach paper
Aluminium foil
➢ 6%
➢ Barrier to Oxygen,
flavour and light
Polyethylene layer
➢ Needed for
lamination process
 P a g e | 36

Internal polyethylene layer

➢ Seals in the liquid.
Polyethylene external
layer
➢ 24% (Total percentage
including all layers)
➢ Protect against
outside moisture
Paper board
➢ 70%
➢ Provide stiffness,
strength and sustainability
➢ Maintains distinct
standard shape of the package
Polyethylene adhesive layer
 P a g e | 37

➢ Lamination layer
➢ Creates a strong adhesion
in Aluminium and paper layer
➢ Supports function of
paper by giving it strength.
➢ Prevents moisture to
reach paper
Aluminium foil
➢ 6%
➢ Barrier to Oxygen,
flavour and light
Polyethylene layer
 P a g e | 38

➢ Needed for
lamination process
Internal polyethylene layer
➢ Seals in the liquid.
Polyethylene external
layer
➢ 24% (Total percentage
including all layers)
➢ Protect against
outside moisture
Paper board
➢ 70%
➢ Provide stiffness,
strength and sustainability
 P a g e | 39

➢ Maintains distinct
standard shape of the package
Polyethylene adhesive layer
➢ Lamination layer
➢ Creates a strong adhesion
in Aluminium and paper layer
➢ Supports function of
paper by giving it strength.
➢ Prevents moisture to
reach paper
Aluminium foil
➢ 6%
 P a g e | 40

➢ Barrier to Oxygen,
flavour and light
Polyethylene layer
➢ Needed for
lamination process
Internal polyethylene layer
➢ Seals in the liquid.
POLYETHYLENE EXTERNAL LAYER
➢ 24% (Total percentage including all layers)
➢ Protect against outside moisture
PAPER BOARD
➢ 70%
➢ Provide stiffness, strength and sustainability
➢ Maintains distinct standard shape of the package
POLYETHYLENE ADHESIVE LAYER
➢ Lamination layer
➢ Creates a strong adhesion in Aluminum and paper layer
➢ Supports function of paper by giving it strength.
➢ Prevents moisture to reach paper
ALUMINUM FOIL
➢ 6%
➢ Barrier to Oxygen, flavor and light
 P a g e | 41

POLYETHYLENE LAYER
➢ Needed for lamination process
INTERNAL POLYETHYLENE LAYER
➢ Seals in the liquid.

6.2. STERILIZATION OF TETRA PAK CARTONS

In order to Protect Juices for a long time, it is essential to sterilize Tetra Pak cartons and
equipment to make them free from micro-organisms. For this purpose, H2O2 is used which is a
strong oxidizing agent. H2O2and its free radical derivatives react with cell membrane lipids and
proteins causing cell membrane to rupture. This mode of action is very effective in the killing of
a wide range of micro-organism. Concentration and pressure of H202 should be regularly
inspected during the production by the instrument aerometer. If the concentration of H2O2 is
below 32% or above 48% it should be replaced with fresh H2O2.
Precaution
• H2O2 can cause burns, eye damage and ingestion may be fatal
• When handling H2O2 always wear the proper personal protective equipment at all time
Storage
• H2O2 should be stored in a cool and dry place away from incompatible material

6.3. HACCP CHECK DURING ASEPTIC FILLING

➢ CCP (Aseptic filling)
➢ Critical limits
➢ H2O2 concentration (30-50%)
➢ H2O2bath temperature (84-88°)
6.3.1. FILLING TESTS
Following two tests are performed to check the sealing status of Tetra Pack Paper.
➢ Conductivity test
➢ Ink test
CONDUCTIVITY TEST
 P a g e | 42

• Leakage in package or damage to the inner plastic layer, a current will follow through the
circuit, by ampere meter
• The salt solution and the Aluminum foil in package material conduct the current through
the circuit
• If current pass then packet has defect if not then it is perfect
• To perform this test at events as package material changes
INK TEST
1. Ink test to be used to detect and locate damage (creaks, pin holes, seals etc)
2. Take a packet and milk drain after this cut it both side
3. Then insert needle of injection fill with test ink
4. Then fill LS with ink, Note leakage
5. If there is leakage in LS then ink will be flow out from LS

CHAPTER NO: 7
QUALITY TESTING METHODS
These test performed on daily basis and badge to badge
 Titration
 Determination of SO2
 Brix (Refractometer)
 Purity of Hydrogen Per Oxide (H2O2)
 Tetra Pack Seal Checking
 P a g e | 43

 Determination of PH
 Determination of TDS
 Appearance, Odor & Taste of Juices
 Water Hardness
 Analysis of CIP Solution
 Acidity of juice/drink/fruit pulp & concentrate
There are some other quality tests which are performed only on weekly or monthly
basis like:
 Arsenic Test (Water Test)
 Chlorine Test (Water Test)
 Calibration of PH meter (Determination of Acidity)

7.1. Titration
Purpose: To determine the purity of Acid/Base
Scope: NaOH, HCl, H2SO4, HNO3 etc. (all acids and bases)
Apparatus: Weighing Balance, Conical Flask, Burette, Volumetric Flask, Pipette
Reagents:
Phenolphthalein 1%: Dissolve 1g Phenolphthalein in 100ml Ethanol and
neutralize it with 0.1N NaOH solution
NaOH 0.1N: Take 0.1N ampoule of NaOH, pour it into 1000ml volumetric flask
and make volume up to 1000ml with distilled water.
H2SO4 0.1N: Take 0.1N ampoule of H2SO4, pour it into 1000ml volumetric flask
and make volume up to 1000ml with distilled water.
Procedures:
 Take 2 to 4g representative sample and dilute to 100ml with distilled water in
 volumetric flask.
 Take 1ml of diluted sample with help of pipette in conical flask.
 Add 2-3 drops of Phenolphthalein solution in it.
(- In case of Acid sample titrate it against 0.1N NaOH to permanent pink color
end point.)
(- in case of Base sample titrate it against 0.1N H2SO4 to colorless end point.)
 P a g e | 44

 Note the burette reading.

Calculation
Calculate the purity of Acid OR Base as under:
Purity %age = Burette Reading x 0.1N x Gram equivalent weight of sample x100
Weight of sample x 1000
……………………………………………………

7.2. DETERMINATION OF SO2

Purpose: To check concentration of Potassium Metabisulfite (To heck SO2 Concentration Also)
Scope: To determine the Free Sulphur dioxide in food samples
Reagents:
Sodium carbonate: This reagent is used to create an alkaline environment in the solution being
tested. The alkalinity helps to liberate any free SO2 that may be present, allowing it to be
detected by subsequent reactions.
Starch: Starch is used as an indicator to show the endpoint of the titration. When all the SO2 has
been neutralized, the solution changes from blue to colorless, indicating the endpoint of the
reaction.
Sulfuric Acid: Sulfuric acid is used to react with the free SO2 in the solution being tested. The
acid converts the SO2 into sulfuric acid, which can then be titrated with iodine solution.
Iodine Solution: Iodine solution is used as a titrant to measure the amount of SO2 in the solution
being tested. The iodine solution reacts with the sulfuric acid formed in the previous step, and the
amount of iodine required to neutralize the sulfuric acid is a measure of the amount of SO2 in the
original sample.In summary, these reagents work together in the testing method to create an
alkaline environment, react with the free SO2, and measure the amount of SO2 present in the
sample.
Procedure:
 Weigh 5g for pulp/50ml for juice sample in a conical flask
 Dilute with distilled water.
 Put 1ml of starch indicator, 5ml of 1:3 Sulphuric Acid, and add 0.5g of
 sodium carbonate in the sample.
 Titrate immediately by adding drop by drop of 0.02 N Iodine solution.
 Continue titration until color changes to dark blue black which persists for 30 seconds.
 P a g e | 45

Calculation:
 Amount of SO2 can be calculated as follow:
 Free SO2 volume of 0.02 N Iodine used × 10 X 12.8
 Free SO2 volume of 0.02 N Iodine used × 12.8
 What is 12.8 = 1ml of Iodine titrant correspond to 12.8 mg of SO2 that’s why
we multiply volume used of Iodine with 12.8

………………………………………………………………………………….

7.3. BRIX (REFRACTOMETER)

Purpose: To examine brix of juice/drink/fruit pulp & concentrates

Scope: Juice/Drink/Fruit Pulp & Concentrates

Apparatus: Pipette 10ml, Ice Box, 1L Beaker, Digital Refractometer, 5000-Alpha

by Atago (Germany)

Procedures:
 Take well mixed representative sample.
 Place two drops of sample on the prism of refractometer.
 Set temperature of refractometer 20°C.
 Select the program “%mas Sucrose” with the help of “SW4” key.
 Press “Start” to get Brix value and note.

Precaution:
 Clean the prism of refractometer with Ethanol before taking each reading.
 Always take well shake sample
7.4. PURITY OF HYDROGEN PER OXIDE

Purpose: To determine the purity of Hydrogen Peroxide

Scope: Hydrogen Peroxide

Apparatus: Thermometer, Hydrometer, Graduated Cylinder, Plastic Beaker

1000ml
Procedures:
 Take a representative sample to be analyzed in a sampling beaker.
 Pour sample into a graduated cylinder and allow it to flow over the top.
 Note the temp. of the sample in cylinder.
 P a g e | 46

 Gently lower the Hydrometer into cylinder and wait till it comes to rest.
 On resting, read off Hydrometer degree on the scale at the surface level of H2O2
in cylinder.
 Purity %age can be determined from attached table carrying specific gravity
and percent purity relationship at observed temperature.

………………………………………………………………………………………….

7.5. DETERMINATION OF PH
Purpose: PH is the measure of Hydrogen ion concentration present in
food sample.
Scope: To determine the pH of Fruit juices, marmalades, sauces, and
other products.
Apparatus: Beaker, pH meter, Buffer solution pH 4 and 7, Distilled Water.
Calibration:
 Power on the pH meter.
 Wash the electrode with distilled water.
 Dip the electrode in the buffer solution of pH 7 and then pH 4 one by one.
 Calibrate the meter using calibrate button appropriately.
 Now take out the electrode, rinse it with distilled water and dry with tissue
paper.
Procedure:
 Stir the sample solution before dipping the pH meter electrode in it.
 Dip the electrode in the sample solution for 1-2 minutes.
 Note the reading, when it becomes stable on display of pH meter.
 Repeat the procedure and record the readings in formats.
Calculation:
PH reading is taken directly from the pH meter screen.

……………………………………………………………………………….

7.6. DETERMINATION OF TDS

Principle: Brix is the measure of concentration of total soluble solids in a solution
 P a g e | 47

or sample.
Scope: To determine the total soluble solids of juices, sauces, jams and other food
products of liquid or semi solid nature.
Apparatus: Beaker, Refractometer, Distilled Water, Sugar standard solution, glass
rod.
Calibration:
 Clean the prism of Refractometer with distilled water.
 Dry it with tissue paper.
 Put sugar standard solution or distilled water on the prism and spread it with
help of glass rod.
 point the Refractometer towards the light source.
 Note the reading on the Refractometer with one eye open and one eye closed.
 If the reading is according to the standard solution, then proceed to check the
sample and if it is not then adjusting the scale with the help of screw driver.
Procedure:
 Clean the prism of the Refractometer with distilled water.
 Dry it with tissue paper.
 Take sample in beaker and put it on the prism of Refractometer.
 Turn towards the light source.
 Note the reading on the Refractometer scale.
 Record the reading and repeat if required.

………………………………………………………………………………………

7.7. APPEARANCE, ODOR & TASTE OF JUICES

Purpose: To check the suitability of Juices/drinks for further processing or release to the
market.
Scope: Juices / Drinks
Apparatus: Water bath, Thermometer, Beaker 500-ml.
Procedure:
 Heat sample to 35 - 40 °C.
 Stir it; examine it for color, taste and smell.
 P a g e | 48

 Normal juice/drink have a pleasant aroma; taste similar to the actual fruit.
Color standards comparable to the Pantone Color Guide numbers:
 Mango…..............128 U
 Orange.................130 U
 Apple......................470 U

…………………………………………………………………………………………

7.8. DETERMINATION OF WATER HARDNESS

Purpose: To check the hardness of water
Scope: Raw Water, Boiler Water, Feed Water etc.
Apparatus: Burette, Pipette, Conical Flask
Reagents:
Buffer Solution (pH 10):
Dissolve 70g of NH4Cl in 568ml of ammonia solution and make volume up to 1000ml with
distilled water in volumetric flask.
EDTA:
Dissolve 4g EDTA, 0.5g NaOH & 0.1g of MgCl2 in distilled water and make volume up to
1000ml with distilled water in volumetric flask.
Eriochrome on Black-T:
Dissolve 0.2g of Eriochrome Black-T in ethanol and make volume up to 100ml with Ethanol in
volumetric flask.
Procedures:
 Take 50ml of water to be tested.
 Add 2ml of Buffer Solution.
 Add 4-5 drops of indicator.
 Titrate it with EDTA solution till the color changes from wine red to blue.
 To obtain total hardness as Calcium and Magnesium multiply the burette reading with 20
 P a g e | 49

……………………………………………………………………………………………..

7.9. ANALYSIS OF CIP SOLUTION:

Purpose: To check the strength of CIP solution
Scope: CIP Solutions (HNO3, NaOH)
Apparatus: Titration Flask, Pipette, Burette, Beaker, Titration flask
Reagents
NaOH 0.1N
Take 0.1N ampoule of NaOH, pour it into 1000ml volumetric flask and make volume up to
1000ml with distilled water or Dissolve 4 gram of NaOH in 1000ml distilled Water.
H2SO4 0.1N
Take 0.1N ampoule of H2SO4, pour it into 1000ml volumetric flask and make volume up to
1000ml with distilled water or Dissolve 2.77 ml of H2SO4 to 1000mL of Water. Add water first
and pour acid on inner wall of container.
Phenolphthalein 1%:
Dissolve 1g of Phenolphthalein in Ethanol and make volume up to 100ml with
Ethanol in volumetric flask.
Procedures:
 Take 1ml of CIP solution to be tested in titration flask.
 Add few drops of Phenolphthalein indicator. In case of Caustic, titrate it against 0.1N
H2SO4 to colorless end point, and in case of HNO3 titrate it against 0.1N NaOH to
permanent pink color end point and note the burette reading.
Calculation:
 In case of Caustic calculate the strength of solution as under
Caustic concentration (%age) = burette reading x 0.4
 In case of Acid calculate the strength of solution as under
Acid Concentration (%age) = burette reading x 0.63
(Calculation is based on the formula N1 V1 = N2 V2)
 P a g e | 50

………………………………………………………………………………………………….

7.10. ACIDITY OF JUICE/DRINK/FRUIT

PULP & CONCENTRATE

Purpose: To determine acidity% of juice/drinks/fruit pulp and concentrate.
Scope: Juices/Drinks/Fruit pulp & concentrates
Apparatus: Glass beaker 100ml, 10ml pipette, pH meter
Reagents:
NaOH 0.1N :Take 0.1N ampule of NaOH, pour into volumetric flask and make volume up to
1000ml with distilled water.
Procedures:
 Take 10ml of representative sample in case of Juice/Drink or 10g of
 representative sample in case of Fruit Pulp/Concentrate in 100ml glass beaker.
 Add approximate 90ml of distilled water and mix it.
 Titrate it against 0.1N NaOH till pH 8.2.
 Note the burette reading.
Calculation:
Multiply the burette reading with below mentioned factor as the case may be to get acidity%.
Factor for Apple concentrate OR Apple Juice/drinks = 0.067
Factor for Red Grape concentrate OR juice = 0.075
Factor for other fruit pulp/concentrate or Juices = 0.064

……………………………………………………………………………………….

7.11. ARSENIC TEST

Sample material:
 Drinking water and mineral water
 Spring water and well water
 P a g e | 51

 Groundwater and surface water

Reagents and auxiliaries
Please note the warnings on the packaging materials! The test strips and test reagents
are stable up to the date stated on the pack when stored closed at +15 to +25 °C.
Package contents: Tube containing 100 test strips
 1 bottle of reagent As-1 1
 bottle of reagent As-2
 1 bottle of reagent As-3
 1 red dosing spoon
 1 green dosing spoon
 2 reaction bottles with screw caps
 Other reagents: Arsenic standard Titrisol® for 1000 mg/l As, Cat. No. 1.09939
Procedure:
 Pretreated sample 60 ml Fill the reaction bottle to the mark.
 Reagent As-1 2 drops 1) Add and swirl.
 Reagent As-2 1 level red Add and swirl until the reagent is dosing spoon completely
dissolved.
 Reagent As-3 1 level green dosing spoon. Add and immediately reclose the reaction
bottle with the screw cap.
 Flip up the black test strip holder integrated in the screw cap, with the white dot facing
you. Immediately insert the test strip into the opening, reaction zone first, as far as the
mark and flip the test strip holder down completely. Leave to stand for 20 min, swirling
two or three times during this period.
 Avoid any contact between the test strip and the solution.
 Remove the strip, briefly dip into distilled water, shake off excess liquid, and determine
with which color field on the label the color of the reaction zone coincides most exactly.
(Read off the corresponding result in mg/l As. 1)
 Hold the bottle vertically while adding the reagent.
……………………………………………………………………………………………………..

7.12. DETERMINATION OF CHLORIDE IN WATER

Purpose: To check the Chloride Contents in Water
 P a g e | 52

Scope: Raw Water, Boiler Water, Feed Water etc.

Apparatus: Glass Beaker, pH meter, Conical Flask
Reagents:
NaOH 0.1N: Take 0.1N ampoule of NaOH, pour it into 1000ml volumetric flask and make
volume up to 1000ml with distilled water.
AgNO3 0.1N: Take 0.1N ampoule of AgNO3, pour it into 1000ml volumetric flask and make
volume up to 1000ml with distilled water.
Potassium Chromate 10%: Mix 10g of potassium chromate in distilled water and make up
volume up to 100ml with distilled water in volumetric flask.
PROCEDURES:
 Take water sample in 250ml beaker and raise pH to 8.3 by adding 0.1N NaOH
 Take 50ml of water sample of 8.3 pH in flask. Add 3~4 drops of 10% potassium
chromate and titrate with 0.1N AgNO3 to brown red end point.
 Note the burette reading and take it as sample reading.
 Take 50ml of distilled water, add few drops of 10% Potassium Chromate and titrate
with 0.1N AgNO3 to brown red end point. This will be the blank sample reading
CALCULATION:
Calculate the chloride contents as below
Chloride ppm = (Sample Reading – Blank Reading) x 35.46 x 2

……………………………………………………………………………………………….

7.13. NITRATE TEST FOR NITRATE IN NATURAL, DRINKING

AND WASTE WATER:
Nitrates are normally present in natural, drinking and waste waters. Nitrates enter water supplies
from the breakdown of natural vegetation, the use of chemical fertilizers in modern agriculture
and from the oxidation of nitrogen compounds in sewage effluents and industrial waters.
Nitrate is an important control test for water supplies. Drinking waters containing excessive
amounts of nitrates can cause methaemoglobinaemia in bottle-fed infants (blue babies).
The EEC has set a recommended maximum of 5.7 mg/l N (25 mg/l NO ) and an absolute
maximum of 11.3 mg/l N (50 mg/l NO ) for nitrate in drinking water
Method
 P a g e | 53

 In the Palintest Nitratest method nitrate is first reduced to nitrite, the resulting nitrite is
then determined by a diazonium reaction to form a reddish dye.
 The reduction stage is carried out using the unique zinc-based Nitratest Powder, and
Nitratest Tablet which aids rapid flocculation after the one-minute contact period.
 The test is conducted in a special Nitratest Tube - a graduated sample container with
hopper bottom to facilitate settlement and decanting of the sample. The nitrite resulting
from the reduction stage is determined by reaction with sulphanilic acid in the presence
of N-(1- naphthyl)-ethylene diamine to form a reddish dye.
 The reagents are provided in a single Nitricol tablet which is simply added to the test
solution.
Test Procedure
1. Fill the Nitratest Tube with sample to the 20 ml mark.
2. Add one level spoonful of Nitratest Powder and one Nitratest tablet.
3. Do not crush the tablet. Replace screw cap and shake tube well for one minute.
4. Allow tube to stand for about one minute then gently invert three or four time to
aid flocculation. Allow tube to stand for two minutes or longer to ensure complete
settlement.
5. Remove screw cap and wipe around the top of the tube with a clean tissue.
Carefully decant the clear solution into a round test tube, filling to the 10 ml mark.
6. Add one Nitricol tablet, crush and mix to dissolve.
7. Stand for 10 minutes to allow full color development.
8. Select wavelength 570 nm on Photometer
9. Take Photometer reading in usual manner (see Photometer instructions).
10. Consult Nitratest calibration chart (Transmittance-display photometer only).
 P a g e | 54

………………………………………………………………………………………………….

7.14. TEST FOR MAGNESIUM IN WATER

0 - 100 mg/l
Magnesium is a widely occurring natural element and is found in most water supplies.
Magnesium salts contribute to the hardness of water and higher levels of magnesium will be
found in hard water areas.

Scale formation in heating and steam raising equipment is promoted by the presence of
magnesium salts in the water.

Magnesium salts do however, have a lower scale forming tendency and calcium salts. The
Palintest Magnecol test provides a simple means of measuring magnesium levels in water for the
range 0 - 100 mg/l Mg

Method
 The Palintest Magnecol test is based on a simple colorimetric procedure.
Magnesium reacts with an organic reagent to produce an orange coloured
complex
 The reagent itself is yellow and thus over the range of the test a series of colour
from yellow through to orange is produced.
 The color produced in the test is indicative of the total magnesium concentration
and is measured using a Palintest Photometer.

Reagents and Equipment Palintest

 Magnecol Tablets Palintest Photometer Round Test Tubes, 10 ml glass (PT

515)
 Measuring Syringe, 1 ml (PT 361)

Test Instructions
 Using the measuring syringe take a 1 ml sample of the water being tested.
Transfer to the round test tube and make up to the 10 ml mark.
 Add one Magnecol tablet, crush and mix to dissolve.
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 Stand for five minutes to allow full colour development and the slight turbidity to
clear. Do not disturb the sample.
 Select wavelength 520 nm on the Photometer.
 Take the Photometer reading in the usual manner (see Photometer instructions).
 Consult the Magnecol calibration chart. (Transmittance-display photometer only)

………………………………………………………………………………………………

CHAPTER N0: 08
DISPATCH AND QUALITY ASSURANCE

DISPATCH AND QUALITY CHECK:

 Check the product for physical appearance: Inspect the juice for any signs of
contamination, such as discoloration, sediment, or foreign particles.

 Conduct a sensory evaluation: Assess the aroma, taste, and texture of the juice to ensure
that it meets the required quality standards.

 Measure the pH: The pH of the juice should be within the acceptable range, which can
vary depending on the type of juice.
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 Check the total soluble solids (TSS): The TSS of the juice should be within the
acceptable range, which can also vary depending on the type of juice.
 Conduct a microbiological analysis: Sample the juice for bacterial and fungal
contamination to ensure that it is free from harmful microorganisms. This analysis should
be conducted by a qualified laboratory.
 Verify the labeling: Check that the product label contains accurate information, such as
the ingredients, nutritional information, and expiration date.
 Verify the packaging: Check that the packaging is intact, clean, and free from defects.

CHAPTER NO: 09
SHELF LIFE AND PRODUCT LABELING

9.1. SHELF LIFE STEADY (1 YEAR)

To achieve a steady shelf life of one year, juice manufacturers like TOPS must ensure that their
products are properly processed, packaged, and stored. Here are some key factors that can affect
the shelf life of juice:

Processing: The juice should be properly pasteurized or otherwise heat-treated to destroy any
harmful microorganisms that may be present.

Packaging: The juice should be packaged in airtight containers to prevent contamination and
spoilage. The packaging should also be able to protect the product from light, which can cause
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discoloration and nutrient loss.

Storage: The juice should be stored in a cool, dry place away from direct sunlight and other heat
sources. The temperature of the storage area should be consistent and within the range
recommended by the manufacturer.

Preservatives: Some juice products may contain natural or synthetic preservatives to help extend
their shelf life. These preservatives should be used in accordance with all applicable regulations
and safety guidelines.

Microbiological testing: Regular testing of the juice product for microbial growth and spoilage
can help identify any potential issues before they become a problem.

9.2. LABELING/ NUTRITION:

Product name: The label clearly states the name of the juice product.

Net contents: The label state the net quantity of the product, typically in fluid ounces, milliliters,
or liters.

Ingredients: The label include a list of all ingredients in the product, listed in descending order
by weight.

Nutritional information: The label should include a nutrition facts panel that lists the amount of
calories, fat, cholesterol, sodium, carbohydrates, fiber, sugars, and protein per serving.

Allergen information: The label clearly state if the product contains any common allergens,
such as milk, eggs, or nuts.

Country of origin: The label state where the product was manufactured or produced.
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Expiration date: The label includes an expiration date or a "best by" date to inform consumers
of the shelf life of the product.

Storage instructions: The label include instructions for storing the product, such as refrigeration
or avoiding exposure to direct sunlight
.
Contact information: The label includes the name and contact information of the manufacturer,
distributor, or importer of the product.
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CHAPTER NO: 10
DUTIES
OUR DUTIES
Process Control

• Ensure production of all products as per all standards and specifications

• Ensure proper verification and record keeping of all products for verification
• Ensure recipe control in all products
• Ensure proper control and identification of products of all stages during production
• Data collection, analysis and communication in case of problem to the concerns
• Ensure hygiene practices in the process
• Ensure proper housekeeping and safe handling of materiel in the process.
Dispatch of finished products
• Ensure proper release of products as per procedure of product release
Laboratory management
• Housekeeping, proper labeling, and record keeping of all equipment’s and chemicals used
in Laboratory.
• Record keeping of all the tests and results being performed.
• Calibration of all equipment’s.
Trainings
Trainings of quality inspectors about
• Process control and verification
• Sampling plan and implementation
• Identification and control of non-confirming products
Record keeping
Documents related to
• Customer complains
• Design and development activity
• Trainings of inspectors
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CHAPTER 11
SWOT ANALYSIS
11.1. STRENGTHS

Leading Beverage Brand owning the evolution of beverage in Pakistan.

Early adopters of new technology, advanced production units with experienced food
technologists proving their experience in beverage.
TOM recall among Juice & Drinks Brands through presence in print and presence in food
festivals, exhibitions local and international
Largest Distribution Network providing Nationwide coverage. Effective On time delivery
and round the Clock customer services proving professional management.
vast range of quality with a choice of flavors within them.
Stability of production
Less turnover of the employees
Highly skilled labor
Talented marketing managers
Qualified finance staff
Professionalism in the employees
Motivated sale team
There is complete motivated sale team in the Top’s Limited which always do their best
job for the promotion, increasing demand, targeting, focusing needs and
according to the customer need the suggest renewing the products, packing labeling etc.

11.2. WEAKNESS
Has been slow in acquiring efficient processes in the brand building area.
Products launched by force of Sales Team & Competitors (when need is raised)
Large Product Range lacking proper planning, strategy, product positioning
causing hurdles in brand building process
Information Flow
Confused Branding resulting in the fading of image such as other food
products not being highlighted as standalone brands from the house of Top’s.
Over work burden on the employees due to limited strength of the workers
No employee backs up plan
Consequences for efficiency and equitable distribution of growth.

11.3. OPPORTUNITIES
Consumers are more receptive towards the change due to media and competition.
Weak Brand Loyalty,
Product range,
Product Quality
To increase the skilled labor
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To use the motivational techniques. (Employee of the month, incentive plans

motivate to perform the above standard
Company exist in very financial products (liquor division, glass division) it provide a
better opportunity to the company.
Company has power to lead their competitor
Company has options for the choice customer
Stability through increased brand awareness, market penetration and Service offerings
Regional Expansions
Production Volumes
Higher Profits
Increased Market share
To create the awareness
Emphasizes on the business ethics

11.4. Threats
Low Operating cost, Trade discounts offered by the competitors.
Barriers to entry are very low in the industry
Extension of accessibility networks by other brands.
Customers have shown high affinity to better/new image brands
Some products may lose focus in a particular category by new arrivals. As the planning
lacks.
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CONCLUSIONS:
The production& quality control Department of TOPS seems to be catering to the needs and
wants of the customer &employees very effectively and efficiently. But issues like decentralized-
decision making is still lacking. The control is mostly in the upper levels. But the good aspect is
that they treat their lower levels in a nice manner. Also the production and quality control
Department is still going under its initial changes and need time to get settled in the organization.
As the technological advancement, is getting more intense with the passage of time, the
production department& quality control of TOPS. is trying its best to settle the employees within
the organization according to this advancement. During my stay at Tops Food & Beverages
Company, it was a great learning experience for me. I learned full of the process of Fruit and
Flavored Juice producing industry which was indeed very useful to me. I also learned some
Quality Control & Safety Lab and Microbiological Lab tests, which are very helpful for me for
my experience. It was a wonderful experience working in a Juice manufacturing company.