Project Report on In-Plant Training

Superior Drink Pvt. Ltd.

Butibori MIDC, Nagpur 441108

Submitted to

Sau. K.S.K alias “Kaku" College of Food Technology,

Beed (M.S.)-431 122

Submitted by
• OMKAR VAJINATH SHELKE -2020FTKK036
• MOHIT SHANTARAM SHIRALE- 2020FTKK038

Training Period:1st January 2024 to 15 April 2024

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 ACKNOWLEDGMENT

We sincerely express our deepest sense of hearty gratitude to the following people for
supporting and guiding us ahead in the journey of making the project report of Industrial
In-Plant training.

I am very much thankful to Dr. G. V. Salunke (Joint-Secretary, SAKVP Beed) for their
valuable guidance, keen interest and encouragement at various stages of my In-
Plant Training period.
There is very special respect and great fullness in my heart for the respected
Mr.V.P.Raut . (In-Plant Training Guide). He took interest in checking minute details of
training report and gave me guidance throughout the training report. I express
deep and sincere gratitude to Dr. Z. H. Syed (Principal, Sau. K.S.K. alias "Kaku"
College of Food Technology, Beed.)
I also extend my thanks to Mr. V.P.Raut (Training and Placement Cell In-Charge).
permitting us to do our
training in Superior Drink PVT. LTD., Nagpur.

We would also like to thank all the professors of our college for supporting and guiding
us throughout our Diploma .

We are grateful to the General Manager of SDPL, Mr. Rajeev Dumbhare & Mr. Srikant
Swain (Quality manager) who provided us with the opportunity to work in such a friendly
environment and also always be indebted to Mr . Atul Sahurkar (HR department)
who manage our training so efficiently.

We are also thankful to all section In-charges and operators who gave us positive
response and guidance during our training period.
Last but not the least, we express our deep feelings of love and affection to our beloved
parents for providing us valuable opportunities which helped us to stand out on our own
feet this stage.

Thanking you!

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 DECLARATION

We solemnly declare that we have undergone the in-plant training with respect from
1st January 2024 to 15th April 2024 at ‘Superior Drinks Pvt. Ltd. Butibori, Nagpur’ to complete
the requirement, of course, in-plant training in the food processing plant.

Further, we declare that this report is the written-up observation of us during in-
plant training. The report has not been submitted to any degree or diploma of any
other university nor has data been derived from any other project.

Place :

Date: / 2024

Signature

Student Name.
Omkar.V.Shelke
Mohit.S.Shirale

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 INDEX

SR NO. CONTENT PAGE NO

1. OBJECTIVES OF IN-PLANT TRAINING 5

2. INTRODUCTION 6-8

3. PRODUCTS OF COCA-COLA 9-10

4. INCOMING PACKAGE QUALITY PLAN (IPQP). 11

5. RETNABLE THE MATERIALS 12-16

6. WATER TREATMENT PLANT (WTP) 17-28

7. RAW SYRUP & READY SYRUP 29-32

8. GLASS BOTTLE LINE (RGB) 33-36

9. OLYETHYLENE TEREPHTHALATE LINE (PET) 37-41

10. PACKAGED DRINKING WATER (PDW) LINE 42-46

11. CLEAN IN PLACE (CIP) 47-49

12. OPRP &CCP 50

13. EFFLUENT TREATMENT PLANT (ETP) 51-58

59-60
14. BOILER

15. CHILING4PLANT 61-62

16. MICROBIOLOGY LABORATORY 63-69

CONCLUSION 70
17.
 OBJECTIVES OF IN-PLANT TRAINING

The objectives of I an industrial training program for B.Tech (food Technology) are:

➢ To give quality to the consumer and satisfy the nutritional need.

➢ To develop the students as skilled professionals through practical work experience

in real-life situations.

➢ To play a vital role for an organization to achieve the target goal.

➢ To mold the students as job providers rather than job seekers.

➢ To develop technical and managerial competence in students in the

commercialization of technologies.

➢ To train the students in high-quality entrepreneurship skills in all the aspects of

enterprise management.

➢ To cultivate capabilities suiting emerging job market and build entrepreneurship

spirit and business management competence among students in that they are able

to create employment for themselves and others.

➢ To adopt and face the challenges given by the boss.

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 INTRODUCTION
History of Coca Cola :-

The Coca-Cola Company is an American based multinational beverage corporation and

manufacturer, retailer and marketer of non-alcoholic beverage concentrates and syrups.
The company is best known for its flagship product, Coca-Cola invented in 1886, by
pharmacist John Stith Pemberton in Columbus Georgia. The Coca-Cola formula and
brand was bought in 1889, by Asa Candler who incorporated the Coca- Cola Company in
1892. Besides its namesake Coca-Cola beverage, Coca-Cola currently offers more than
500 brands in over 200 countries or territories and serves over 1.7 billion servings each day.
The Coca-Cola Company is headquartered in Atlanta, Georgia, United States. The company
operates a franchised distribution system dating from 1889 where The Coca-
Cola Company only produces syrup concentrate which is then sold to various bottlers
throughout the world who hold an exclusive territory. The Coca-Cola Company owns its
anchor bottler in North America, Coca-Cola Refreshments.

The first Coca-Cola recipe was invented in Columbus, Georgia at an Eagle drug store &
chemical company by, John Stith Pemberton; originally as a coco wine called Pemberton’s
French Wine Coca in 1885. It is produced by The Coca-Cola Company in Atlanta, Georgia
and is often referred to simply as Coke. Coca-Cola was bought out by businessman Asa
Griggs Candler. The company produces concentrate, which is then sold to various
licensed Coca-Cola bottlers through the world. The bottlers, who hold exclusive contract
with the company, produces the finished product in can and bottles from the concentrates
in combination with water and sweetener. When launched, Coca Cola’s two key
ingredients were Cocaine and Caffeine. The cocaine was derived from the Coca leaf and
caffeine from Kola nuts, hence the name Coca-Cola (the K in Kola was replaced with a C
for marketing purposes). The Divisional headquarter in India is Situated at Gurgaon-
Haryana.

The Coca-Cola Company is the world’s largest beverage company, refreshing

consumers with nearly 500 sparkling and still brands. Along with Coca-Cola, recognized
as the world’s most valuable brand, the Company’s portfolio includes 12 billion dollar
brands, including Diet Coke, Fanta, Sprite, Minute Maid and Georgia Coffee and Tea.
Globally, Coca-Cola Company is the No. 1 provider of sparkling beverages, juices and
juice drinks and ready-to- drink.

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 About Coca-Cola ,
India:-

Coca-Cola India is the Indian version of the renowned Coca-Cola Company, the
Consumer goods firm known across the globe. The Coca-Cola Company started
operating in India in 1950. However, in 1977, they withdrew operations from the country
in protest of regulations and legislation by the Government of India limiting the dilution of
equity of multinational corporations. On October 24, 1993, they decided to re-enter the
market, and have maintained a strong presence ever since.

Coca-Cola India, is one of the country’s leading beverage companies, offering a range of
healthy, safe,high-qualityy, refreshing beverage options to consumers. Ever since its re-
entry in 1993, the Company has gone on to establish an unmatched portfolio of
beverages, refreshing consumers with its leading beverage brands like Coca-Cola, Zero,
Diet Coke, Thums Up, Fanta, Fanta Green Mango, Limca, Sprite, Sprite Zero, VIO
Flavored Milk, Maaza, Minute Maid range of juices, Georgia and Georgia Gold range of
hot and cold tea and coffee options, Kinley and Bonaqua packaged drinking water, Kinley
Club Soda and BURN energy drink.

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 About Superior Drinks Pvt. Ltd, Nagpur:-

UPERIOR DRINKS PRIVATE LIMITED, Nagpur (BUTIBORI) is a Pvt. Subsidiary of the Coca-
Cola Company. It is one of the leading manufacturer soft drink company in Nagpur. This
plant has a largest bottling facility in a country.

Products manufacturer in this company are:-

1) Coca-Cola
2) Thums up
3) Fanta
4) Sprite
5) Limca
6) Kinley water
7) Kinley soda
8) Rim zim

Plant Location: - PLOT NO. B-220, 221, & B-15, MIDC, BUTIBORI, NAGPUR-
441122

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 PRODUCTS OF COCA-COLA
1. Coac-Cola:

The Coca-Cola is world’s favorite drink in beginning in 1886.It is available

packaging materials like glass bottles, PET container, Can. Glass bottles are
available in 200ml& 300ml size. PET bottles are available in commercial size

like
250ml, 750ml, 1 liter, 2 liter. Can is available in 330ml size & fountains are
available in various size.
2. Thums up:
It is most the popular soft drink in India. It has strong Cola taste & made for
pera son with exiting personality. It has strong, fizzy taste. Originally introduced
in 1977, “Thums-Up” was acquired by The Coca-Cola Company in 1993. Thums
Up is known for its strong, fizzy taste and its confident, mature, and uniquely
masculine attitude. Pack size PET 250ml, 750ml, 1 liter, 2 liter.

3. Fanta:
It is identified as Fun catalyst. Fanta stands for its vibrant color, tempting taste
and Tingling bubbles that just uplifts feelings but also helps free spirit thus
encouraging one to indulge in the moment.

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

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5. Limca:
Limca is a lemon- and lime-flavored carbonated soft drink. The soft drink is
manufactured by the Coca-Cola Company and was launched in 1977 under
the name Limca. It has been pleasing the customers with its taste.

6. Kinley Water:
It is packaged drinking water. This water is treated through 5 step process UV
treatment, Reverse osmosis, ozonization, carbon filtration, and sand filtration. So
it has a trust to drink i.e. “Bund Par Vishvas”.

7. Kinley Soda:
It is one of the best sparkling carbonated soft drinks without any added flavor. It
is available in glass bottles and also in PET bottles.

8) Rim zim:
Rimzim is a jeera flavored sparkling beverage and aims to
create unique brand identity in the jeera soda space.¹

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 Incoming Packaged Quality Plan (IPQP)

All raw materials and packaging materials required for manufacture final product;
supplied by approved authorized suppliers only before the utilizing or processing the raw
material we have to check the quality of material by different quality test. All the test
methods are approved by CCI (coca cola India).

Flow chart:

Raw material purchased from approved supplier

|
Material vehicle arrived in the company
|
Sanitation
|
Driver health check-up
|
Consignment goes to store
|
Intimation passed to quality analyst
|
Checking vehicle condition, supplier name & batch no.
|
Sampling by wearing gloves & mask
|
Q ua lity an alys is
___ _____|
| |
Accepted Rejected
| |
Release Q u l ity
A n a l y s is
| |
Material can used in process
||
Accepted. Rejected
| |
Release Batch cancel
|

Material can used in process.

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 THE MATERIALS

The materials are categorized into three sections:-

1) Raw materials
2) Packaging
material 3) Auxiliary
material

Raw materials:-

These are the initial materials which are used to prepare final products. The raw

material
include sugar, concentrate, carbon dioxide and nitrogen.

Sugar:-
Sugar is a vital raw material. Its presence is both functional and provides flavor,
ensuring drinks retain their distinct tastes and characteristics alongside maximum shelf
life. The presence of sugar balances the acidity of the final drink.

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2
Carbon dioxide:-
Carbon dioxide offers to carboed water and to beverages a pleasing flavor. It also protects
from bacteria and microbes; as carbon dioxide. When mixed with water it forms carbonic
acid, which gives fizzy taste to the carbonated soft beverage. The purity of carbon dioxide
should not be less than 99.9%.

Nitrogen:-

Nitrogen has a variety of uses within the beverage industry. Food grade nitrogen has no
detrimental effect on beverages when it is brought into contact with. It is extremely
beneficial in the beverage industry as it can be used to displace oxygen and therefore
prevent oxidation, which causes food and beverage spoilage.

Packaging material:-

This are the material which is used for packing the final product. Packaging material

are
of two types: - 1) Primary packaging material
2) Secondary packaging material
1) Primary packaging material: - Primary packaging is the packaging that most closely
protects the product. It can also be referred to as retail or consumer packaging. Primary
packaging in the beverage industry would be the bottle or can the beverage is stored in.
The label on the bottles or cans is also considered part of the primary packaging.
This includes label,preforms,closures and crowns.

Labels:-
• Printing quality / matter
• Dimensions (length and breadth)
• Color shade
• Total GSM

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• Physical appearance
• Artwork
• Ink Adhesion

Preforms:-
• Weight
• Height
• Thickness
• Polariscopic
• Transparency
• Perpendicularity
• Go No Go

Closures:-
• Weight
• Height
• Visual
• Cracked or broken
• Color of shell and
print
Crowns:-
• Printing matter /
quality • Go no go gauge
test
• Weight
• Liner quality
• Odor
• Artwork

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2) Secondary packaging material: - Secondary packaging is the packaging that holds
together the individual units of a good. It is designed as a means to deliver mass
quantities of the good to the point of sale or end user. Secondary packaging may be
removed from the item without changing the qualities or attributes of the good.

This includes shrink film and stretch film.

Shrink film:-
• Dimensions (length and breadth)
• Total GSM
• Physical appearance
Stretch film:-
• Dimensions (length and breadth)
• Total GSM
• Physical appearance

Auxiliary materials:-
These are the materials which required in between the process and enhance the product
quality. The material like Activated carbon, HCL, Bleaching powder, Lime, Ferrous
sulphate, Caustic flakes/ lye, Divo ultra VB10, Divo LE, Divo AI, Filter sheet, Phosphoric
acid etc.

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1
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 WATER TREATMENT PLANT (WTP)

Beverage water treatment plays a prominent role in the hygienic and efficient production
process as well as for the right taste of the product. Water treatment is a process that
improves the quality of water to make it appropriate for a specific use. The required
treatment technology always depends on the different composition of the raw water
available on site and the requirements of the beverage produced. Every beverage (for
example, mineral water, fruit juices, sodas, soft drinks and beer types) requires
individually tailored water treatment.

Treatment for drinking water production involves the removal of contaminants and
undesirable components, or reduces their concentration and inactivation of any potentially
harmful microbes from raw water to produce water that is pure enough for human
consumption without any short term or long term risk of any adverse health effect. Once
used, all water leaving the plant must be treated to meet discharge limits set by state and
federal regulations.

For many beverage manufacturers, feed water is municipally sourced. Municipal water is
treated according to EPA regulations or equivalent.

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 In this water treatment plant, water production is of three
types:- 1) Treated water
2) RO water
3) Soft water

Treated water:-

Raw water that undergoes processing to meet a specifications. This involves either the
addition of components to the water, subtraction of components from the water or both.

Flowchart of treated
water:-

Raw water sump

tank

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8
 Sugar syrup line CSD (PET) Line RGB line

RO Water :-

Water that has been desalinated by the process of Reverse Osmosis. This involves
forcing salt water to pass through a membrane that has pores to small to allow salt
to
pass through. It involves fairly high pressure across the membrane.

Flow chart of RO water

:-

Raw water sump

tank

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Process of treated water and RO water:-

1) Raw water tank :-

MIDC water is supply to raw water tank. When MIDC water is supply to raw water
tank
there is a dosing of calcium hypochlorite up to 3-5ppm.

Role of chlorination process:-

For chlorination process, calcium hypochlorite is used. It act as a disinfectant. Calcium
hypochlorite is used to kill bacteria, viruses and other microbes in water
.
2) Modular tank :-
After chlorination, raw water is transfer to modular tank. In this tank 30min contact time is
given to calcium hypochlorite and raw water so that calcium hypochlorite dissolve properly
in raw water.

3) Coagulation tank :-
In coagulation tank, suspended solids portion are separated from water. Suspended
particles vary in shape, size, density, source and charge. Chemicals are added to the
water to bring the non-settling particles together into larger, heavier masses of solids
called floc. Then this floc settle to the bottom of the tank. Also organic compounds remove
in coagulation process which cause unpleasant taste, odor and brown discoloration. And
clear water transfer to the clear water tank.
Chemicals which are added in coagulation tank are as:-
• Ferrous sulphate
• Lime
• Calcium hypochlorite

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Role of chemicals :-

• Ferrous sulphate: - It acts as a

coagulant along with floc formulation.
It
helps in settling of particulate matter.

• Lime:-Lime is used to remove carbonate

hardness caused by calcium and
magnesium salts. And it also adjust pH of
water by raising its pH to 10.5-11 thus
controls the environment required for the
growth of bacteria and certain viruses.

• Calcium hypochlorite: - It is bleaching agent and also act as a disinfectant.

Calcium hypochlorite is used to kill bacteria, viruses and other microbes in water.

4) Clear water tank: -

It is only a storage tank which is used to store clarified and chlorinated clear

water.
5) Pressure sand filter: -

It is frequently used to remove

suspended solids from water. The
Pressure Sand Filter consists of a
multiple layer of sand with a variety in
size and specific gravity. These
Filters are designed to remove
turbidity and suspended particles
present in the feed water with
minimum pressure drop. Raw water
flows downwards through the filter
bed and the suspended matter are
trapped in the bed. Filtered water exits the vessel and transfer to process water tank.

2
1
6) Process water tank :-
When filtered water transfer to process water tank there is a dosing of Carbon dioxide to
maintain the pH of water. This water is then transfer to Activated carbon filter.

7) Activated carbon filter: -

The Activated carbon Filters are designed

to remove free chlorine, organic matter,
odor and color present in the raw water and
waste water. Due to its high degree of micro
porosity, activated carbons provide a huge
surface area. Activated carbon filter
operates through adsorption. Then from
here it goes to lead and lag activated
carbon
filter.

8) Lead and lag activated carbon filter: -

The filtered and de-chlorinated water at the outlet of ACF may contain some organics and
pesticides residue. In order to remove disinfectant and de-chlorinate the water, a lead and
lag activated carbon filter is provided. The trace organic matter is adsorbed on the carbon
surfaces thus making it free from organics and pesticides.
After passing through lead and lag activated carbon filter, the water stream is split into
two line:
• CSD line
• Kinley line

• For CSD line: - Water stream goes for further treatment from:
1) 5 micron filter
2) UV treatment
3) 3 micron filter
4) 1micron filter
• For Kinley line: - Water stream goes for further treatment from:
1) UV treatment
2) 5 micron filter
3) Reverse osmosis
4) RO holding tank

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2
Micron filter: -

Micron filters remove dirt, debris and even microscopic particles

from water. The pore size of a filter cartridge is measured in
microns. The smaller the micron rating, the finer the particulate
removed. So, 1 micron filter removed the finer particles from water
than 5 micron and 3 micron filter.

Treated water from 1 micron filter supply to raw syrup, ready

syrup, RGB line, PET line, CIP and laboratories.

UV treatment: -

Ultraviolet water treatment is

the most effective method for
disinfecting bacteria from the
water. Disinfecting your water
with Ultraviolet light is
exceptionally simple, effective
and environmentally safe. UV
systems destroy 99.99% of harmful microorganisms without adding chemicals or
changing your water’s taste or odor.

Reverse osmosis: -

Reverse osmosis (RO) is a water purification process that uses a semi-permeable, thin
membrane with pores small enough to pass pure water through while rejecting larger
molecules such as dissolved salts (ions) and other impurities such as bacteria. By using
force it removes this contaminants from water.

RO holding tank: -
Filtered water from RO supply to this tank and from here filtered water is transfer to PDW
line.

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2
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 Soft water:-

Soft water is water which has relatively low concentration of calcium, iron or

magnesium,
which form insoluble deposits such as scale in boiler, but have higher concentration of
sodium.
Flow Chart of Soft Water :-

Source water (MIDC supply)

Chlorination (OPRP 1) Raw water tank

Modular tank

Pressure sand filter

Activated carbon filter

Softener

Non-chlorinated soft
Chlorination 1-2 ppm (OPRP

3) Chlorinated soft water

water Boiler, Chilling

Bottle washer plant, Chain

lubrication Canteen &
Washroom

Process of soft water :-

• MIDC water is supply to raw water tank. When MIDC water is supply to raw water tank
there is a dosing of calcium hypochlorite up to 3-5ppm.
• After chlorination, raw water is transfer to modular tank. In this tank 30min contact time

is
given to calcium hypochlorite and raw water so that calcium hypochlorite dissolve properly
in raw water.
• The chlorinated raw water is passed through a pressure sand filter to remove suspended

2
5
particles from water.

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5
• The filter water then passed through the activated carbon filter for de-chlorination and
removal of traces organics.
• The de-chlorinated water then passes through an ion exchange based softener for
removal of hardness.
• The soft water is then split into two streams.
• One stream is chlorinated (1-3 ppm) and store in the chlorinated soft water tank.
• The other stream is collected in the unchlorinated soft water tank.
• Chlorinated soft water then supply to bottle washer, chilling plant, chain lubrication
and boiler.
• Non-chlorinated soft water then supply to canteen and washroom.

Softener:-

t is a unit that is used to soften

water, by removing the minerals
that cause the water to be hard.
Softener mainly remove calcium
and magnesium, and sometimes
it also remove iron. Water
softeners are specific ion
exchangers that are designed to
remove ions, which are
positively charged. In water
softening process brine solution
is supply to the softener to
activate resins. The water supply passes through the water softener over resin beds, rows
of resin beads perform an ion-exchange. The resin beads chemically attract the unwanted
‘hard’ mineral ions and exchange them with sodium ions. When the resin beds become
saturated with the minerals, the water softener flushes them out with a salt solution called
brine and the process begins again.

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6
Analysis of sof water :-

Testing parameters:-

• Color: The Color indicates generally the presence of undesirable dissolved,

colloidal and suspended impurities in the water. Examples: Iron turns water to
brown/red, Manganese makes it black and Organics make it yellow.

• Odor and Taste: It indicates generally the presence of undesirable dissolved

substances, such as hydrogen sulphide or sewage contamination. It important
parameter for water quality control in the food and beverage industry.

• Suspended Solids: It includes all matter suspended in water that is large enough
to be retained on a filter with a given porosity.

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• Turbidity: It indicates the level of colloidal matter of organic or inorganic origin. The
Suspended solids & colloidal matter make water turbid.

• pH: It is a negative logarithm to base 10 of the hydrogen ion concentration. The pH

of pure water is 7, pH below 7 makes the water acidic & above 7 basics.

• Alkalinity: It can be defined as the ability of water to neutralize an acid, which

indicates the quantifiable quantities of bicarbonates, carbonate, and hydroxide in
water. It can be determined using Phenolphthalein & Methyl orange indicators.
Phenolphthalein gives the P. alkalinity or P-value. Methyl orange gives the M.
Alkalinity or M value.

• Total Hardness: It indicates the quantities of calcium and magnesium. A part of

total hardness is associated with alkalinity in water and is known as alkaline
hardness, carbonate hardness or temporary hardness. The balance of total
hardness is associated with non-alkaline ions such as chlorides, sulfate etc. and
is known as Non-alkaline hardness or permanent hardness.

• Total Dissolved Solids: It is defined as the total content of dissolved solids in water
which represents all charged ions – Cations, anions as well as uncharged and
molecular species. It is the summation of cations i.e. calcium, magnesium, sodium
and anions i. e chlorides, sulfate nitrates, and uncharged ions as silica.

• Electrical Conductivity: It is representative of the purity of water. Higher the

conductivity, higher the content of ions, higher the impurities in water & vice versa.
An empirical relationship exists between conductivity and total dissolved solids.
Electrical conductivity is temperature-dependent.

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 RAW SYRUP & READY SYRUP

The syrups room are designed and constructed for the preparation of syrups for use in
the production of the final beverage. The syrups rooms cover the complete cycle for the
preparation of the product needed to deliver to the bottling stage by combining several
different technology systems like dissolving and mixing, storage tanks, filtrations and
piping.

The plant is equipped with two syrup rooms:

1) Raw syrup room
2) Ready syrup room

Raw syrup room: -

The syrup is made up of water, sugar, activated carbon powder and Hyflo. This syrup is
prepared by dissolving these ingredients into the water to 65°Brix. It is prepared by
dissolving sugar at 70 to 80°C, and filtering and cooling sugar syrup to 10°C.

Flowchart
:- Treated Water

|
Raw syrup
tank
|
Water heated at 60-
65°C
|
Sugar Dumping as per requirement
|
Sugar + water heated at 75°C (for
30min)
|
Maintain temperature to 85°C OPRP 4
^ |

|
Addition of carbon (0.3% of total sugar) and hyflo (0.25% of total

sugar)
|
Contact time 30min

|
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 Pre-coating of Hyflo (0.15% of total sugar) on filter
press
|
Filtration of syrup through filter press
|
Circulation for 30min
|
Filtered simple syrup passing through PHE
|
Simple syrup temperature maintained to 10-30°C

|
Ready syrup tank

Process: -

1. Carry out CIP of raw syrup tank.

2. Calculate total amount of sugar required to prepare a specific unit of a particular
flavor.
3. Similarly calculate & weigh th e corresponding amount of activated carbon
powder &hyflo for the required sugar.
4. Take sufficient water &separately stir the carbon powder &hyflo in buckets to
remove fines.
5. Add required amount of treated water in the tank &start heating water with
continuous agitation.
6. Start weighing & dumping sugar bags to the tank one by one with agitation.
7. Close the steam valve as the temperature reaches 85℃& give a contact time for 30
minutes.
8. Add 0.3% activated carbon powder &0.25% hyflo total sugar to t h e tank &
allow contact time for 30 minutes.
9. Pre-coat the filter press with 0.15%hyflo of total sugar.
10. At end of contact time re-circulate the sugar syrup tank for at least 20 minutes.
11. Check the appearance of syrup by filtering syrup through 0.45-micron filter paper.
12. If filter paper is not clean then continue circulation.
13. If filter paper is clean then divert the clean syrup to the ready syrup tank through
the plate heat exchanger at 10-30℃.

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 Analysis of Raw
syrup:-

Ready syrup room: -

Raw syrup from raw syrup room is passed to ready syrup tank of ready syrup room. Then
further process take place depending upon product flavor. Final syrup is prepared by
simple syrup, concentrate and water to required brix.

Flowchart
:- Raw syrup
|
Addition of concentrate of required flavor

|
Maintain brix by using treated water
|
Agitation for 1
hr. |
Ready syrup

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1
Process:-

1. Carry out CIP of ready syrup tank.

2. Issue concentration or beverage base from cold storage to the ready syrup room
at least 4 hour prior to preparation of ready syrup.
3. Close the bottom valve of the ready syrup tank at the end of simple syrup transfer.
4. Start agitation &note down simple syrup volume.
5. Ensure the concentration feed trolley has been sanitized & connect trolley to ready
syrup tank inlet.
6. Open concentration can lids.
7. Start agitation of ready syrup tank. Then add concentration to ready syrup tank as
per sequence of addition given in instruction.
8. Ensure that all the parts have been properly flushed into tank.
9. Add the sufficient quantity of treated water to ready syrup through feed trolley.
10. Close bottom valve of ready syrup tank then carry out agitation of syrup for 20
minute.
11. Check ready syrup brix & calculate remaining amount of water added to tank to

get
the final volume.

Analysis of ready syrup:-

3
2
 REUSABLE GLASS BOTTLE LINE (RGB)

A reusable Glass bottle is a bottle that can be reused, as in the case as by the
original bottler or by end-use consumers. Reusable bottles have grown in popularity
by consumers for both environmental and health safety reasons.

Glass bottles is 100% recyclable and can be recycled endlessly without any loss in quality
or purity. Glass is non porous and impermeable, so there are no interactions between
glass packaging and products to affect the flavor of food and beverages. Glass has
almost zero rate of interactions, ensuring that the products inside a glass bottle keep their
strength, aroma and flavor.

The RGBs can be used in two ways after the drink that has been packaged has been
consumed.

• The damaged bottles, with even the slightest of chips, get recycled into new glass
bottles.

• The perfect bottles go through a rigorous cleaning process at the plant, to be

reused as new bottles for packaging.

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3
Flowchart
:-

Pre-lite inspection

3
4
Process:-

1. Empty bottle return from market to industry.

2. Sorting of empty bottle is done

manually.

3. Bottle from case are placed over conveyor, which is known as de-casing. The machine
used is de-caser.

4. Bottles are passed through pre-inspection containing high intensity light where bottles
containing foreign matters or physical impurities are removed manually.

5. This bottles pass through 6 steps bottle washer.

• Pre Rinse: bottles are rinsed with chlorinated soft water through jet pressure:
>2kg/cm^2.
• Pre Soak: Bottles are treated with 1.5-2% caustic, where temperature 50-55℃
is maintained.
• Main Soak: It consist of 2.6-
3% caustic, where temp 71-

74℃ is maintained. In main

soak 0.2% DIVO ULTRA
dosing is done to remove
date code.
• Hydro: In this step caustic is
removed by using water
through jet pressure:
2kg/cm^2.
• Pre Final Rinse: >25ppm DIVO LE dosing is done for shining purpose & DIVO AI
is used to maintain pH: 7-8.
• Final rinse: soft chlorinated water is used through jet pressure>1kg/cm^2.

6. After bottle washing, bottle goes under post light inspection, where bottles that are not
washed properly, contain foreign material are removed manually.

3
5
7. A manually inspected bottle goes through EBI (Electronic Bottle Inspection) machine,
where undesired bottles or caustic containing are returned for washing.

8. A desirable bottle goes through filler machine where bottles are filled
t hrough vent tubevolumetric filler.

9. After bottles are filled crown is placed over the bottles.

10. Date coding is done in such a way that crown is firstly detect and after coding is done
to filled bottles.

11. In final light, final inspection is done to check whether date coding is proper, bottles
are properly filled.

12. Proper filled and date coded bottles are placed in case through case packer machine.

13. Storage is done of the product and dispatched according to requirements.

Parameters:-

36
 POLYETHYLENE TEREPHTHALATE LINE (PET)

PET which stands for polyethylene terephthalate is a form of polyester. It has a number
of benefits for consumers who regularly purchase food and drinks in plastic containers.
PET is extruded or molded into plastic bottles and containers for packaging of food and
beverages of different design and sizes.

PET is the most frequently used packaged material for beverages due to its handling
properties. PET is inert, so it does not react with beverages. It is hygienic and resistant to
attack by microorganisms and will not biologically degrade. As a raw material, it can be
manufactured very efficiently, which not only has a positive impact on the production costs
but consequently also on the sales price of the end products. It is simple to transport and
won’t break easily. PET is recognized by health authorities around the world.

3
7
3
8
 PET CSD: -

• The Preforms used for blowing of bottle is made up of PET (Polyethylene

Terephthalate).

• The Preforms are blown and molded into bottles in KRONES molding machine
.
• Here Bottles are categorized into three, Contour, Splash, and Dimple.

KRONES VOLUMETRIC FILLER:

• The machine consists of 12 molds and 18 capping

heads.
• The machine consists of 90 filler valves.
Steps for bottle blowing are as follows:
1. Preforms heated at a temperature
between 100-125°C.
2. Then preforms are transferred for
molding and molding occurs in three step.
• Pre-blowing of preforms at a
pressure of 10-12 bar.
• Intermediate blowing at a
pressure of 12-18 bar.
• Final blowing is done at
pressure of 25-32 bar.
3. After blowing, the bottles are send to the base cooling section where cold water is used
to cool the base part.
4. The bottles get attach to the filler valve for filling of beverage.

FILLING PROCESS:

The filling process is done in three steps:

1. Counter pressure: Pressurized CO₂ is filled firstly to match the pressure of bottle with
the filler tank pressure and then only the valve gets open for filling.

2. Beverage filling: Beverage fill along with the walls of bottle to prevent the release

of 39
CO₂ from beverage and also reduce product foaming. During filling the CO₂ get replace
back to filler tank.

3. Snifting: The pressure in head space of bottles or foams of CO₂ is removed by snifting.

LINE DETAILS:

• The specialty of this unit is with its high speed. The bottling unit has speed of 450
BPM for 250ml, 750ml.
• Here high speed filler valve is there in absence of vent tube. It has 90 filling valve
and 18 capping heads.
• For detecting the fill level and capping of bottle, sensors are used. If the fill level
detects more or below and if there is any defect in capping of bottle the bottle get
separated.
• The bottles are send to Warmer for the removal of water droplets on the bottle.
• Before going to labeling, the bottle passes through blower where air is blown to
dry the bottle.
• Date code is done with the laser light and after that casing is done according to the
bottle size specification.
• Secondary date code is printed on casing and these casing are kept properly one
above another in palletizer and they are ready to dispatch.

Observations (Tests) are as follows:

• Brix: Degrees Brix is the sugar (sucrose) content of an aqueous solution.

• Gas Volume: Carbonation of beverage (Amount of CO2 present in beverage).
• Net Content: The amount of beverage filled in bottle. Formula for finding Net
content is (Gross weight of bottle- empty bottle weight) / density of beverage.
• Torque: The tendency of force required to open the cap of bottle.
• Caustic Stress Crack: This test is done to check the stress crack resistance.
• Secure Seal Test: Pressure is applied to filled bottle at 100psi for 60 seconds.
• Application Angle
• Top Load (Empty/ Filled)

40
• Bottle Parameter
• Date Code: Date code consist of batch number, time, manufacturing date, use by
date and recycling value.
• Bottle Burst Test:
• Below 1000ml Bottle pressure 13.6 bar for 13 sec, if fails pressure 11.9 bar
• Above 1000ml pressure10.4 bar for 13sec, if fails pressure at 8.6 bar.

Bottle parameters:

4
1
 PACKAGED DRINKING WATER (PDW) LINE

Packaged drinking water is water from any source, which has been treated and
disinfected, a process that could involve filtration, UV or ozone treatment or reverse
osmosis (RO) and then packaged in bottles or pouches, either plastic or glass, for our
consumption. For a product to be considered as “bottled water”, it cannot contain
sweeteners or chemical additives (other than flavors, extracts or essences) and must be
calorie-free and sugar-free.

Kinley water is wholesome and it is enriched with minerals. Every single drop of mineral
water passes through a wide purification process. In this plant, it is packed in polyethylene
terephthalate (PET) plastic.

A rise in health awareness, poor quality of tap water available and increase in
tourism leads to availability of bottled water that have all contributed to the
increase in the per capita consumption of bottled water in India today.

4
2
4
3
Process of PDW: -

For the Package Drinking Water there are so many operations takes place. First R.O
Water Received from WTP in R.O Holding tank at PDW Line. Then after Minerals Dosing
(Calcium and magnesium) water pass through the 1.2 micron and 0.2 micron filter for
remove suspended particles and maintain the Electric Conductivity. After maintaining the
EC its transfer Ozone Reaction tank for the mixing of ozone up to 0.1 to 0.4 PPM .In
Ozone Reaction tank Ozone comes from the Ozonator and mixed with water by
recirculating process. Ozonized water transfer to the Gravity Volumetric filler in which set
of the volume of filling water, after filling liquid nitrogen added for the tightness of bottles
and capping ddidthen goes for inspection , labeling, Coding, & Packaging.

Oxygen Generation:

An oxygen generator is a device that separates oxygen from compressed air using special
selective adsorptive technology called pressure swing adsorption (PSA). The compressed
air used in the oxygen generation process has a similar composition to ambient
environmental air with 21% oxygen and 78% nitrogen.

Ozone generation:

Ozone is produced from oxygen as a direct result of electrical discharge. This corona-
discharge ruptures the stable oxygen molecule and forms two oxygen radicals. These
radicals can combine with oxygen molecules to form ozone.

Ozone reaction with drinking water:

Because of its excellent disinfection and oxidation qualities, ozone is widely used for
drinking water treatment. Ozone can be added at several points throughout the treatment
system, such as during pre-oxidation, intermediate oxidation or final disinfection. Ozone
oxidizes the organic material in bacterial membranes, which weakens the cell wall and
leads to cellular rupture Ozone can effectively kill bacteria as well as Giardia,
Cryptosporidium, parasites, fungi, molds and other microbes. Several federal agencies
have established health standards or recommendations to limit human exposure to ozone.
For drinking water it's standardized up to 0.1 to 0.4 PPM used Ozone.

44
Nitrogen properties:

• Does not react with

water
• Boiling point-195.8°C
PDW Preparation of concentrate:

1. Calcium Chloride Dihydrate ( 5unit -0.929kg)

2. Magnesium Chloride Hexahydrate ( 5unit
-1.250kg)
• Mix 5 unit ( 5 unit Ca+5unit Mg) in 3 lit water

BIS Test for Drinking Water: -

4
5
Line Parameter test: -

Bottle Parameters:
-

46
 CLEANING IN PLACE (CIP)

Cleaning in place is a method of automated cleaning the interior surfaces of pipe, vessels,
equipment, filters and associated fitting, without major disassembly. It cleans equipment
with minimal dismantling and operator/manual involvement. It relies on the principal of
applying a suitable detergent or solvent at suitable flow and kinetic energy application,
pressure and temperature for a determined amount of time to ensure effective cleaning of
system.

In this plant, 3 types of CIP is used:

• Five-step CIP
• Three-step CIP
• Two-step CIP

Five Step CIP: -

It is used in syrup room, Reusable Glass Bottle {RGB} line and Polyethylene
Terephthalate (PET) line. Five steps CIP takes 95 min to complete cleaning.

Process:-

Pre-rinse (For 10min)

|
Hot caustic (For 15 min)
(Caustic concentration: 1-1.5%, In temp: 75°C & out temp:
65°C) |
Cold water (For 10min)

|
Hot water (For 15min)
(In temp: 95°C & return temp: 85°C)
|
Final rinsing (For 10min)

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7
Three Step CIP: -

It is used in syrup room, Reusable Glass Bottle {RGB} line and Polyethylene
Terephthalate (PET) line. Three steps CIP takes 45 min to complete cleaning.

Process:-

Pre-rinse (For 10min)

|
Hot water (For 15 min)
(In temp: 95°C & return temp: 85°C)
|
Final rinsing (For 10min)

Two Step CIP: -

It is only used for Packaged Drinking Water (PDW) Line.

Process:-

Hot water (For 15min)

(In temp: 95°C & return temp: 85°C)
|
Final rinsing (For10 min)

• In CSD section CIP done after every 48 hrs.

• In PDW section CIP done every after 36 hrs.
• When process is on hold or flavor changes CIP is done.
• After CIP is completed water is return to tank and used foe next CIP process.

48
Procedure: -

1. Pre-rinse: In this step treated water is used from recovery tank.

2. Caustic wash: Caustic solution is used from lye tank. Caustic wash return to its
tank and can be reused multiple times, which significantly reduces water, chemical
and energy costs over a single tank system.
3. Cold water: It used water from recovery tank or forward recovery tank. Cold

water
is used to remove residual traces of detergent remaining from caustic wash.
4. Hot water: Hot water used from hot water tank. The water is heated with steam.
Hot water is used to remove remaining particles of any residue or materials.
5. Final rinse: Treated water is used for final rinse. The final rinse water is recovered
and reused as the pre rinse for the next cleaning cycle.

Advantages: -

• Minimizes Mistakes: Automating cleaning reduces the chance of human error that
can contribute to an unsafe product.
• Keeps Employees Safe: Reduces chemical exposure by containing cleaning
solutions within the system.
• More Production Time: As less production time is lost to cleaning, more time is
spent making product.
• Product Quality: Reliable and repeatable cleaning means sustainable product
quality and consistency. Less contamination means fewer product recalls and
• Higher brand confidence.
• Utility Savings: Water and energy usage is reduced through repeatable cycle.

49
 OPRP & CCP

Operational Pre Requisite Program (OPRP): -

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.

In this plant there are total 7 OPRP: -

• OPRP-1: WTP-(3-5ppm Chlorine at Raw Water Tank)

• OPRP-2: WTP-(>70W/m2 UV at UV Light treatment)

• OPRP-3: WTP-(1-3 ppm Chlorine at Soft Chlorinated Water Tank)

• OPRP-4: Raw Syrup (85ºC Temp for 30min after sugar mixing)

• OPRP-5: RGB-(2.6-3% caustic at 72ºC - Washer)

• OPRP-6: RGB-(Proper working of EBI)

• OPRP-7: RGB-(Crowning-GO-NO-GO)

Critical Control Point (CCP): -

A critical control point is defined as a step at which control can be applied and is essential
to prevent or eliminate a food safety hazard or reduce it to an acceptable level. A CCP
decision tree is not a substitute for expert knowledge.

In this plant there are total 3 CCP: -

• CCP-1: WTP-(3-5ppm Residual free chlorine at After

PSF) • CCP-2: RGB-(Glass Fragment After 3rd round)

• CCP-3: PDW-(0.15-0.4ppm Ozone in final Bottle)

50
 EFFLUENT TREATMENT PLANT (ETP)

Effluent treatment plant is a process design for treating the industrial waste for its reuse
or safe disposal to the environment. ETP is designed to remove the physical, chemical
and biological materials prevent in the effluent. ETP are used in food industries and
chemical industry to purify water and remove toxic and non- toxic materials or chemical.
• Influent: Untreated industrial waste water.
• Effluent: Treated industrial waste water.
• Sludge: solid part separated from waste water by ETP.

5
1
5
2
RO plant
:-

5
3
Process:-

1) ETP sump tank: -

In this tank all used water is collected and from here this water is transfer to screen
bar section
.
2) Screen bar section:
Screening is the filtration process for the
separation of coarse particle from effluent. It
removes all physical impurities from water.
This chamber consist two screen-
i) Coarse screen ii) Fine screen
• Coarse screen: - This removes larger
impurities of size 8mm.
• Fine screen: - This removes smaller
impurities of size 5mm.

3) Skimmed oil section:

Water from screen bar section transfer to this
section. In this section oil and grease is separated
from water as it inhibit the growth of culture.

4) Equalization tank:
In this tank, effluent become homogeneous and neutralize. Effluent is neutralize
by adding acid (HCl) or alkali (lime) which helps to increase or decrease the pH of
water
.
5) Primary clarifier:
It is used to remove suspended
material from effluent. For this
Alum and Polyelectrolyte dosing is
done. Thus the sludge that settles
down pass through filter press.
This sludge is dried and stored in

5
4
a room. And the water that is remove from filter press get collect in Skimmed
oil section.
• Alum: - It help to remove color
• Polyelectrolyte: - It is used to settle the suspended matters and reduce TSS.

6) Aeration tank:
Clear water from primary clarifier
transfer to aeration tank. Here
aerobic bacteria is used to
stabilize and remove organic
material present in waste water.
Dosing of culture, urea, and Di-
ammonium phosphate (DAP)
and sugar is done.
• Urea: - It is used for clear water
formation. • DAP: - It is used for growth of
bacteria.
7) Secondary clarifier:
It has same role as primary clarifier. Generally, the remaining suspended particles
which does not settle in primary clarifier is removed in this clarifier. The clear water
transfer to chlorination tank.

8) Chlorination tank:
It is used to kill microorganisms with the help calcium hypochlorite. Calcium
hypochlorite acts as a disinfectant.

9) De-chlorination tank:
Water from chlorination tank transfer to this tank. It is used to remove chlorine.
Sodium Meta bi-sulphate (SMBS) dosing is done to remove chlorine.

10) Treated water tank:

Water from de-chlorination tank transfer to this tank. It is only a storage
tank.

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5
Fish pond: -

Before discharging water for further use it is transfer to fish pond. This is done to
check the quality of water. If fish is survive then the quality of water is good. And
water can be discharged for further use. If fish is not survive it indicates the quality
of water is poor and it is again treated.

11) After quality is check it transfer to Central effluent treatment plant (CETP), irrigation
and RO plant.

12) Treated water transfer to RO plant for further treatment. RO plant consist of
sand filter, carbon filter and cartridge filter.

13) Sand filter:

First treated water transfer to the sand filter. It removes turbidity and fine particles.

14) Carbon filter:

Water from sand filter transferred to carbon filter. It helps to remove fine particles
and total dissolved solid particles from water.

15) Cartridge filter: It is also used to filter the

water.

16) Dosing of antiscalant and SMBS: In between the transfer of water from cartridge
filter to RO membrane dosing of antiscalant and SMBS takes place. It is done to
remove the scalent that blocks the pore of the membrane.

17) RO membrane:
Water passes through RO process which has a polyamide membrane with pore
size in the order of Å.

18) Water that is good quality and safe to use is permitted water that goes to the
tertiary tank and then to the chilling or cooling tank.

19) The water that is not in good quality or not safe that is rejected water and send
to screen bar section for further treatment.

56
 Analysis of waste
water:-

Testing parameters:-

1) Chemical oxygen demand (COD):- The COD is an indicative measure of the amount of
oxygen which is needed for the oxidation of all organic substances in water in mg/l or
g/m3.

2) Biological oxygen demand (BOD):- It is a measure of the amount of oxygen

required to
remove waste organic matter from water in the process of decomposition by aerobic
bacteria.

3) Oil and grease: It is the quantity of free or combines oil or grease per liter of effluent
water
.
4) Dissolved Oxygen (DO): Dissolved Oxygen is the amount of gaseous oxygen (O2)
dissolved in the water.

5) Mixed Liquor suspended solid (MLSS):- MLSS is the concentration of suspended solids

5
7
in the tank during the activated sludge process, which occurs during the treatment of
wastewater. MLSS consists of microorganisms and non-biodegradable suspended
matters.

6) Total suspended solid (TSS):- Total suspended solids (TSS) is the dry weight of
suspended particles that are not dissolved in a sample of water that can be trapped by
a filter that is analyzed using a filtration apparatus.

5
8
 BOILER
A fire-tube boiler is a type of boiler in which hot gases pass from a fire through one or
more tubes running through a sealed container of water. The heat of the gases is
transferred through the walls of the tubes by thermal conduction, heating the water
and
ultimately creating steam.

The boiler is used for the generation of steam. In the boiler by using fuel & non- chlorinated
soft water .steam is generated .this steam is provided for bottle washing, syrup heating,
and water heating for CIP. If the pressure of boilers is low it starts & if pressure is high it
stops.

59
Boiler is used for a generating steam which is used for various purposes in industry which
are as follows:

• Heating caustic/water in bottle

washer

• Dissolving and pasteurization of Raw Syrup

• Heating of Caustic/water for CIP system

• Degassing and sanitation of activated carbon filters

• For evaporators in CO2 bulk storage

tank

• For sterilization of Closures

60
 CHILLING PLANT

In technical terms it works on the principle of Vapor Compression Cycle.

The function of chilling plant is to send cold glycol at -1 to -4 𝐶° to the PHE for

• Chilling of beverage so that CO2 dissolves easily into

it. • Syrup preparation.

6
1
Working of Chilling plant:

Working of Chilling plant:

1. Ammonia act as a primary refrigerant in the chilling plant. As ammonia cools
the
glycol, the ammonia having a low pressure is transferred to the accumulator.
2. The accumulator prevents the compressor from failure due to liquid slugging.
Accumulator sends the vapors of ammonia to the compressor.
3. The compressor accepts the low-pressure ammonia and converts it into high
pressure by reducing the volume of ammonia and sending it to the condenser.
4. Condenser converts the vapor ammonia into a liquid with the help of water from
the chilling tower. As the heat is transferred from the refrigerant to the water
medium, the gaseous refrigerant condenses to the liquid inside the condenser.
5. Thus, the chilled liquid ammonia is received in the receiver tank.
6. The chilled liquid ammonia is transferred to the P.H.E. to cool the glycol.
7. Thus, the glycol is sent to the plant for beverage cooling and syrup preparation.

The output glycol we get at ~

-2ºC.

Cooling tower:

Key points in working of cooling tower.

• Heat and Mass transfer.

• 1 kg of water on evaporation removes approximately 530 kcal of heat.
• The heat given up by the water falling inside the towers equal the heat gained by
the air rising through the tower.
• The hot water entering the tower is distributed within the structure in a manner that
exposes a very large water surface to the air passing through.
• Water distribution accomplished by means of spray nozzles or distribution pans
and by means of various types of “fill.”
• This fill increases the exposed water surface to maximize contact with the air,
increasing the rate of heat transfer.

6
2
 MICROBIOLOGY LABORATORY

Microbiological testing is essential in the beverage industry to ensure the safety of

products. It helps to keep the beverage industry safe and prevents dangerous pathogens
from finding their way into the food chain. It is a vital part of the industry that protects
people and businesses by ensuring safety at all times.

Microbiological analysis cover the use of biological, biochemical or chemical method for
the detection, identification or enumeration of microorganisms. It is often applied to
disease causing and spoilage microorganisms. It include tests that check for E. Coli,
salmonella, pseudomonas, and other common pathogens that can contaminate
beverages. This testing ensure the continued safety of your food products along the
supply chain.

The purpose of microbiological analysis should be to identify and restrict harmful

microorganisms, which can spoil beverage and ensure safety from waterborne disease.

Disease causing microorganisms:-

63
 Equipment: -
Equipment used in microbiology laboratory are as:-

1. Laminar air flow: Laminar air flow cabinet is defined as enclosed work bench
which is used to create a contamination free work environment through installed
HEPA (High Efficiency particular Absorbing) filters that capture all particles entering
the cabinet.

2. Autoclave: Autoclave is a machine that uses moist heat or steam under pressure
to kill harmful bacteria, viruses, fungi, and spores on items that are placed inside a
pressure vessel.

3. Incubator: Incubator is a device used to grow and maintain microbiological cultures

or cell cultures. The incubator maintains optimal temperature, humidity and other
conditions such as the CO2 and oxygen content of the atmosphere inside

4. Biological oxygen demand (BOD) incubator: BOD Incubator are used to maintain
temperature for test tissue culture growth, storage of bacterial cultures and incubation
where high degree of constant temperature accuracy is required. It has both heating
and cooling system.

5. Hot air oven: Hot air ovens are electrical devices which uses dry heat to sterilize
laboratory equipment and other materials.

6. Heating mantle: Heating Mantle used to apply heat to container as an alternative

to other form of heated bath.

The plant is equipped with two microbiology

laboratory:- • Carbonated Soft Drink (CSD) laboratory
• Bureau Indian Standard (BIS) laboratory

64
CSD laboratory: -

CSD laboratory is for carbonated drink. It includes testing from raw water to finished
product. This laboratory include test for:-
1. Escherichia coliform
2. Yeast
3. Mold
4. Total plate count

Procedure:-

Sanitizing surface of laminar air flow and filter assembly

|
Pour required media on petri plates

Place Filter paper on filter assembly

|
Filter the required sample through 0.45μ filter paper
|
Using forceps place filter paper on media
|
Keep petriplates in incubator
|
Remove and count colony forming unit.

Testing Parameter:
-

65
BIS laboratory: -
BIS laboratory is for kinley water testing.
Testing Parameter: -

66
Air Monitoring:

Air monitoring is the determination of pollutant levels by measuring the quantity and types
of certain pollutants in the surrounding and outdoor air. In industries it detect the presence
of toxics and monitor air quality to ensure the contamination free environment. This leads
to an increase in productivity, reduced equipment damage and effective regulatory
appliances. It provides evidence on the current levels of contaminants and provides
policy-makers with information on how to better manage air quality in their regions.
Generally in plant air monitoring perform in following section:
1. PDW Line
2. PET Line
3. RGB Line
4. Sugar dumping area
5. WTP Plant
6. Raw syrup & Ready syrup room

Generally, we detect total plate count and yeast &

mold.

Testing parameters:
-

6
7
Swab test: -

Swab test is the counting of total number of aerobic bacteria, yeasts and molds on any
surface. The purpose of swab is to detect the presence of microorganisms in place where
hand cannot reach and that cause disease. Swabbing collects unseen dangers of
equipment, plant and hand, and the lab can grow them up to a detectable level. The
primary use of the techniques is to determine whether cleaning &sanitizing has been
effective. In this laboratory we used stick swab.
Generally we take swab of filler and sniff.

Testing parameters:
-

Hand swab: -

Personal hygiene of operators play an important role in production as they can spread
food borne disease. Hand Swab sample is taken by wiping the swab all over the palm.

Testing parameters:
-

68
Validation and verification of autoclave:-

1) Validation of autoclave:
A quality assurance procedure used to ensure that the autoclave reaches adequate
temperature for an adequate amount of temperature for adequate amount of holding time
to sterilize biological agents and waste. Autoclave validation is done in every three
months.

For autoclave validation we use ampule containing nutrient broth, pH indicator, sugar
& spore of non-pathogenic organism, Geobacillus Stearothermophilus.

Procedure:
• Keep 2 ampules in autoclave at 121°C and 15psi for 15min.
• After autoclaving, take out ampules from autoclave.
• Take this 2 ampules (which is autoclave) and the control ampule (which is
not autoclave). Keep this 3 ampules in incubator at 60°C +- 2°C for 48 hours.
• Compare autoclave ampules with control ampule.
• Ampules which kept in autoclave their color doesn’t change which means
autoclave is working. If its color change then it means autoclave is not
working properly.

2) Verification of autoclave:
Autoclave verification is done to ensure the proper working of autoclave. For verification
of autoclave chemical indicator strip used. Autoclave verification is done every day.

Procedure:
• Keep chemical indicator strip in Autoclave in screwcap bottle for 15min at 121°C
and 15psi
• Then take out the sample and check the color.
• If color changes from white to black then autoclave is properly working. If not then
it indicates that autoclave is not properly working.

69
 CONCLUSION

• It was a wonderful & memorable experience for us, undergoing industrial

training in SUPERIOR DRINKS PVT LTD, NAGPUR (BUTIBORI).in last Four month.

• We gained a valuable practical experience and it has made me aware

that production and time management is very important for all industries.

• In last occasion I learned how to work in welfare established

industry.

• It was also taught us the difference between theory and actual experience
knowledge that we have gained in this industry.

• The helping and cooperative nature of all workers and staff members to clear
all the fundamental concepts cannot be overlooked.

• They all are extremely Welcoming & Helpful and offered me invaluable
career advice.

• They had specified me deep knowledge of each and every product, which will
definitely help in future life. We are very lucky to have In-plant Training in such
an established plant.

• This training has definitely increase our interest in pursuing career in Beverage
industry.

• Once again Thank you for an excellent Four

months.

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0