REPORT ON THE INDUSTRIAL VISIT TO
BIDADI
FROM THE CLASS OF BCOM F&A A “
”
TEAM COMPRISING
ABHIRAM.R-1110536 ANIRUDH.G-1110557 ANJANA MENON-1110521 MENON-1110521 DHILIP KUMAR-1110569 HARSHA RAJ T N-1110558 SIDDESH WALI-1110548 TEJA M GOWDA-1110563 GOWDA-1110563
COMPANY PROFILE OF COCA COLA : AN OVERVIEW ‘John Syth Pemberton’ first introduce d the refreshing taste of coca cola in Atlanta, Georgia. It was of 1886 when the pharmacist concocted caramel-colored syrup in a
three-legged brass kettle in his backyard. He first ‘distributed th e new product by carrying Coca- Cola in a jug down the street to Ja cob’s pharmacy. For five cents, consumers could enjoy glass of Coca-Cola at the soda fountain. Whether by design or accident, carbonated water was teamed with the new syrup, producing a drink that was proclaimed “Delicious and Refreshing” . Dr. Pemberton’s partner and bookkeeper, Frank M. Robinson suggested the name and penned ‘Coca-Cola’ in the unique flowing script that is famous worldwide today. In 1886 sales of Coca-Cola averaged nine drinks per day. That first Dr. Pemberton sold 25 gallons of syrup, shipped in bright red wooden kegs. Coca-Cola is a carbonated soft drink sold in stores, restaurants and vending machines internationally. The Coca-Cola formula and brand was bought in 1889 by Asa Griggs Candler (December 30, 1851 - March 12, 1929), who incorporated The Coca-Cola Company in 1892. Hindustan Coca-Cola Beverages Pvt. Ltd, Bidadi is the largest bottling partner of The Coca-Cola Company in India. It is a part of The CocaCola Company’s Bottling Investments Group (BIG) and responsible for the manufacture, package, sale and distribution of beverages under the trademarks of The Coca-Cola Company. The Coca-Cola Company claims that the beverage is sold in more than 200 countries. It is produced by The Coca-Cola Company in Atlanta, Georgia, and is often referred to simply as Coke or (in European and American countries) as cola, pop, or in some parts of the U.S., soda.
THE INDUSTRIAL VISIT :
The visit commenced at 9 am in the morning with our able professors Ms Sameena,Mr Thangjam and Mr Prashanth Bharadwaj leading the visit and through the pleasant NICE road our travel bus reached Bidadi in a span of a hour and a half. The instructions given were to switch off our cellular phones and then proceed to security checks after which we were seated in the reception where they had a slide show for us, which took us through the history of the Coca Cola company, the manufacturing process, and the most talked about controversial pesticide residue in soft drinks. After the show a plant employee gave us an in-depth tour of the plant. It was interesting to see how the bottles first get cleaned, filled, capped and labeled. The plant has a capacity to bottle 1564 bottles per minute!!! That's quite fast. However, the plant runs in full capacity in summer.Two lines were not in operation due to maintenance activity and it was told to us that maintenance is performed in the time duration of half an hour. What surprised us was the fact that out of all their cool drinks Fanta is the most produced followed by Thumb's Up, and then Coke. The production they said was as per the demand they recieved. The bottling process they explained was that first a small plastic tube is injected with hot air under pressure in a predesigned mould into the shape of the bottle. Then the chilled drink is filled in (for the fruit drink Maaza, the drink is filled at 90 degrees to kill bacteria) and labeled. The process of manufacture includes key components like extensive treatment of the raw water, preparation of the syrup, the container preparation process, filling, inspection, coding and filling the bottles into cases. The finished product is then dispatched to the warehouse before it departs on to its final destination – the consumer through a network of depots, distributors and retailers. The waste water is processed through an elaborate waste water processing system to ensure the output water conforms to the world class standards.
INDUSTRIAL VISIT HIGHLIGHTS :
Their(COCA-COLA) mission and vision statement s were placed as notice boards and caught our attention immediately ’
Mission: We the team of the HCCBPL, Bidadi shall ensure efficient and effective use of water during beverage manufacturing process in our plant by continually improving the infrastructure, monitoring and controlling the consumption of water
in individual area and imparting training to our associates.
Vision: Efficiently reduce, re-use, recycle and recharge water as a responsible corporate citizen.
There was a lot to learn from these statements and showed the level of social responsibility coca cola had.
The guide inside the factory premises explained to us about the basic structure of the plant at Bidadi.
The plant occupied an area of about 16 acres of land
Retainable glass bottles are produced at a rate of 600/day. Pet bottles have production capacity of 200/day.200 Maaza bottles are produced in 1 minute and kinley production is 185/minute.
Currently the number of production lines at the plant included lines for coke plastic and glass and tetrapack, sprite plastic and finally two lines for fanta and one for maaza and mineral water as well.
A newly installed technically sophisticated production line has been introduced in the plant
Coke has 6 brands in India namely Coca-Cola, Fanta, Thumbs up, Sprite, Maaza and Minute maid Pulpy Orange
The Process of manufacture as explained by the guide was in the following phases
It was told that they mainly procured their raw material from Pune and Chennai.
Water drawn from the premises of the plant had to undergo three layers of filtering before it was used for the soft-drink manufacture.It is non chlorinated and is from the River Cauvery. Hindustan Coca- Cola Beverages has its own water treatment plant where water is imported from the water tanks situated 3km far from the plant. The water received is treated scientifically for the manufacturing process as well as for washing the bottles
The first one being through a layer of activated carbon filter then primary filtering which is a kind of basic filtering and finally ultra violet filtering. Sugar which is taken only from authorized dealers is then made into the form of a syrup to be mixed with water at temperatures between 70-80 degree Celsius to ensure free of germs.
Highest quality refined sugar is mixed with treated water to form simple syrup which is pumped through filter to ensure its purity and clarity. Carbonated filter paper is used for this purpose. At this stage different proportion of sugar is added for manufacturing the syrup of concerned drink like; coke, sprite, fanta etc. Distinctive blend of ingredients are mixed with syrup to form Coca-Cola syrup. Now this syrup is pumped to the De-Aerator Proportioner Cooler carbonator where a proportionate amount of de-aerate water is mixed which is further cooled and carbonated. Now the syrup is ready for filling.
The corresponding bottles that are made from a plastic “free form” is washed thoroughly starts to move along the production line awaiting the chamber in which the mixture of Carbonated soft-drink [CSD] which includes the primary mixture of water with sugar syrup and the secret concentrate is filled into the bottles.
Finally the bottles get sealed and stay in the final segment of production line at which they are labeled and packed ready for sale. Currently there are two machine running 600 bottles per/min [plastic] and 250 bottles per/min [glass]
The bottles filled are further moved to packing place where it is packed in carton boxes. At a time 36 units are packed in 3 boxes. Each box contains 12 units. These boxes are further sent to the distributors, if not then stored in store room at room temperature
The guide at Coca-Cola also explained about production and packing process of Coca-cola and its associated brands. They also threw light on Industrial Safety and Health, Waste Management and CSR Activities of the Company. It was also observed that the plant was fully automated and required minimalistic human intervention . We were amazed at the speed at which the process occurred and how the automated systems could work according to the requirements. The manufacturing process adopted by them was the batch process.
The Plant has Implemented "The Coca-Cola Quality System"(TCCQS) which is a Quality Management System practiced by all the Bottling plants across the world. It encompasses both External & Stringent Internal Quality Management Systems. A surveillance audit for all the above systems is being carriedout at regular frequencies. (The Coca Cola Environmental Management System), eSLP (Environment Safety & Loss Prevention), WRM (Water Resource Management), EMS (Energy Management System), Waste Management, Waste water Management etc. are in practice. These above mentioned Internal QM Systems
have been implemented for achieving the continual improvement which will be audited internally to identify further areas of Continual Improvement. The Plant Layout. Followed in Hindustan Coca- Cola Beverages Pvt. Ltd., Bidadi, Bangalore is cellular manufacturing layout., where the cells functions somewhat like a product layout., within a larger shop or process layout. Manufacturing of Coca-Cola Pet, washing as well as inspection of Coca-Cola bottles and filling of bottles, pet and can line too occurred under straight line layout. A FEW DIM MOMENTS:
Negative attributes observed at the branch included heavy pollution from chimney smoke which would prove a threat to the environment and a slight mismanagement of resources with wastage. The human resources employed needed better training and competency than what was witnessed during our visit.
LEARNING EXPERIENCE :
In all the industrial visit was a major learning experience for the entire team as we learnt various aspects in a manufacturing industry and also met theory with practicality. The progress of technology amazed us and showed how deep rooted technology had synced with the modern process of production. The speed at which each item was produced was enthralling to watch and to think the errors that would be commited in comparison to a human manufacturing approach would be absolutely minimalistic left us in awe at the marvels of the human mind. We also learnt that rumours circulating around the unhygienic production of cocacola beverages were not to be believed and that the process was completely safe and healthy and in accordance with the norms specified by the relevant authorities. It was also observed that Coca-Cola observed safety norms very strictly and gave clear cut instructions to every visitor to the factory and suitable tactics to escape any calamity
CONCLUSION
In all the visit to the coca cola factory at Bidadi was an enriching experience and we could all say that we had gained precious knowledge with the visit.We hope to visit back someday in order to gain more experience and knowledge on the making of the world’s most favorite drink!.
