28/07/2014
INDUSTRIAL TRAINING REPORT On “QUALITY CONTROAL AND MENUFACTURING FOR CSD & NCB BEVERASES” PepsiCo Indi !o"din#s P$% L%d ' B(p)*
Submitted To
Mr. Nitesh Jain Quality Assurance Assurance Manager PepsiCo Bazpur
For The Partial fulfillment of the Degree of Bachelor of Technology Technology in Biochemical Engineering
Submitted by
M!AN A"M#$ B.Tech %th semester Bipin Tripathi &umaon nstitute nst itute o' Te Technology( chnology( $)arahat
AC+NO,LEDGEMENT It is said said that that behi behind nd any acco accomp mpli lish shme ment nt of any any eor eortt ther there e are are some some dedicated individuals who put in their best to get the job done.
M* D + Sin#in#- .AM AM/' M* M* I also also want ant to expre press my ful full than thanks ks to M*
P*$een S-)0" E1e2)%i$es M* P*$end* Sin#- .3i2*o4io"o#is%/ for giving me their support during my training period in this industry. industry. Finally we would like to express my wholehearted thanks to M* Ni%es- 5in Q)"i%6 6' PIP ltd. !"a#pur$ for providing this excellent opportunity Manager Q)"i% and and a co%o co%ope perrativ ative e envir nviron onm ment ent alo along with with gui guidanc dance e and and cons consttant ant encouragement and helpful discussion throughout our training. &ast but certainly not the least I am highly grateful to all supporting sta of this industry for their sincere cooperation. I am sincerely indebted to them.
Place (ate
Imran 'hmed
INDUSTRI INDUSTRIAL AL TRAININ TRAINING G AT MENUF MENUFACTUR ACTURING ING AND QU QUALIT ALITY Y CONTROAL FOR CSD & NCB
CERTIFICATE OF ORIGINAL ,OR+ )his is to certify that the industrial report entitled * QUALITY CONTROAL AND MANUFACTURING FOR CSD & NCB BEVERAGES + is done by I3*n A-3ed student of BTe2- Bio2-e3i2" En#inee*in# 7%se3es%e* under the supervision of D + Sin#- .AM/ ' M* P*$een S-)0" nd E1e2)%i$es M* P*$end* Sin#- .3i2*o4io"o#is%/ )o the best of my knowledge and belief the work has been complete by this candidate himself.
D%e8 M* Ni%es- 5in P"2e8 Mn#e*9 Q)"i%6 Pepsi,o India holdings Pvt. &td. "' -P/
Inde1 N*.
Topics
Page no.
+
ntroduction about PepsiCo
+,-
-
ater treatment plant -.+ Brei' out line
0,2
-.- B*!# #// -.0 ST*!A1# TAN&
0
2
Types o' )ater 0.+ !a) )ater 0.- Treated )ater 0.0 So't )ater 0.2 So't reco3ery )ater Syrup preparation
4,+%
+%,+5
4
!M6PM testing7s
+5,-4
%
1lass line
-4,-8
Conclusion
-9
!e'erences
-5
NT!*$:CT*N Soft drinks constitute one of the largest beverage industries in the world today. Treendous advances have taken !lace in the !rocess technology in the soft drink industries in the !ast one or two decades. The beverages are divided into two grou!s i.e. carbonated soft drinks like "e!si# $ountain %ew# $. orange# 7 &! etc. ' non(carbonated soft drink like Slice. The a)or ingredients of soft drinks are a* +ater b* Sugar or sugar substitute c* ,arbon dio-ide d* lavor eulsion and eulsifiers e* ,oloring agents f )Ac i dsandpr e s er v at i v e s
*rigin *' Pepsi n orth ,arolina# $r. ,aleb radha who was a !haracist by !rofession invented a new beverage in year 188# which was called 3rads %rinks 5evocation of a digestion 6 aiding enye !e!sin*. This brads drink was later called 3""S ,9:;. "e!si ,ola tradeark was registered in 10<.radha believed arketing would be the key to "e!si 6 cola. =e s!ent > 100 on advertising when he sold only 40#000 liters of syru!. n 10?# radha build "e!si@s first bottling !lant. Three 5<* ore !lants followed soon and in 107# he was selling ?0#000 liters !er year. n 10# he hired a new advertising agency. Troubles started at the end of the world war 1 st when radha overstocked sugar at high !rice which subseAuently di!!ed to rock botto in 120. by 122# the co!any was insolvent and by 12<# it went bankru!t. radha returned to his !haracy. Boy $egargell# a wall street broker ste!!ed in and reorganied the co!any. =owever the co!any was running a loss each year and with the stock arket crash in 12. $egargell was not able to u!kee! the co!any any longer in 1<0.
ndian Story o' Pepsi n 177# a change in governent at the center led to the e-it of ,oca 6 ,ola which !referred to Auite rather to dilute its eAuity to 40C in co!liance with the oreign -change Begulation ;ct 5B;*. The beginning of 180@s saw the birth of another ,ola drink# 3Thus &!. The D9:% S"9T !eo!le launched it in 178(7# as 3Befreshing ,ola in 178# "arle led the ndian soft(drinks arket 5share <
by the &.S. headAuarters $, to enter ndia. "e!si,o would have an eAuity holding of <C# "un)ab ;gro ndustries ,or!oration 5";,* 20C and Foltas 24C. The rest had to be financed !rivately fro loans. ; !ro)ect a!!roval board was finally set in ebruary 188. "e!si@s share which have been originally )ust under 40C and ";,
Pepsi Bottling Plant( Bazpur "e!si,o ndia =olding "vt. :td 5a!ur* is a green ,99 5 COMPANY OWNED BOTTLING OPERATION * !lant of !e!si cola international. t is located on eria road# a!ur about ?? k. away fro anital# &ttarakhand . The occu!ied area is absolutely !o!ulation free. t is one of the foreost anufactures of non alcoholic corbonated beverages. The annual !roduction of beverage is 10 illion cases. The !lant was o!ened in the year 17 and bottling started fro ? $ay 18. The !lant of "e!si,o ndia =olding "vt :td. at a!ur has an effective an!ower of ore than <00 which includes both line and staff authorities. The achieveents of the !lant includes# nternational Iuality ;ward 5I;* for housekee!ing# Iualifying ; audits# Iuality and ood Safety ;ward# ;$; Begion# ".
The plant layout is di3ided into 'ollo)ing areas; 1. ;dinistrative lock 2. +.T." <. &tility ;reasE %.D.# oiler# B;, 4. .T.". ?. Syru! Boo
J. $anufacturing ;reaE :ine 1E "T J00 l :ine 2E "T J00 l# 1ltr# 2ltr# 2.2?ltr :ine
• •
+. !M6PM T#STN1S B$ 6"$ is raw aterial ' !ackaging aterial which is subsistently is a inventory Auality control ethod for assuring good Auality easure in inventory ' !ackaging aterial 2.+. Tests Per'ormed *n Sugar
Test,+; Color Test Purpose; The color test easure the aount of i!urities in sugar which is a !riary indication of sugar Auality. Sources o' color; 1. "lant aterials 2. Befining !rocess by !roduced Procedure; 1. %issolve sugar sa!le in water to ?0 bri-. 2. != ad)ustent if necessary. <. ilter sa!le through vacuu assebly 50.4? filters*. 4. %egas sa!le. ?. ill sa!le in cell. ( 9ne of sa!le to be analyed. ( 9ne of distilled water for reference. J. "lace cells in s!ectro!hotoeter 5420 *. 7. %eterine reading by using a!!roved calculation Color : <
!eading = +>>> ?A cm cell length@= ?B g6ml solid@
+here# ;# sa!le cell !ath length in c # sa!le solids concentration in g/l. Test,- Turbidity Test
Purpose; To deterine aount of hae/cloudiness in sa!le caused by containation. #uipment; 1. S!ectro!hotoeter 2. Facuu !u! <. iltration unit Procedure; 1. %issolve sugar sa!le in water to ?0 bri-. 2. %eaerate sa!le <. ill sa!le cells ( 9ne of sa!le to be analyed. ( 9ne of distilled water for reference. 4. "lace cells in s!ectro!hotoeter and deterine unfiltered reading at 420 K. ?. ilter sa!le through vaccu assebly 50.4? filters*. J. ill sa!le cells ( 9ne of sa!le to be analyed. ( 9ne of distilled water for reference. 7. "lace cells in s!ectro!hotoeter and deterine filtered reading5Lcolor@*. 8. ,alculate turbidity
Turbidity <
?!eading be'ore 'iltration reading a'ter 'iltration@ = +>>> ?cm cell length@ = ?g6ml solid@
Test,0 Taste( *dor( and Appearance Test
Purpose; To ensure that no gross containation in sugar e-ists. Speci'ication E 1. Taste of an acidified 10 bri- solution should be sweet with no !resence of abnoral flavors. 2. o off odor should be !resent. <. Sugar should be free of foreign aterial
#uipment;
9dorless !lastic cu!s Procedure; 1. +eight 10 g of sugar. 2. ;dd 0 l treated water. <. ;dd .04@ = ?)ater conducti3ity@ Ash < +%%%.8 !esult and calculation, ;shC O P corrected conductivity ,orrected conductivity O conductivity of sa!le ( 0.
,orrected conductivity O 2<.? 6 0.
Ash
O 21.22/1JJJ.7 O 0.0127C
Test,2 Taste( *dor( and Appearance Test
Purpose; To ensure that no gross containation in sugar e-ists. Speci'ication E 1. Taste of an acidified 10 bri- solution should be sweet with no !resence of abnoral flavors. 2. o off odor should be !resent. <. Sugar should be free of foreign aterial #uipment; 9dorless !lastic cu!s Procedure; 1. +eight 10 g of sugar. 2. ;dd 0 l treated water. <. ;dd
Test,4 Be3erage Dloc Purpose; The beverage floc test serves as an indicator of sugar which is likely to fro a floc in beverage. eet sugars ty!ically have a greater tendency to fro floc than cane sugar. #uipment; 1. alance 6 ca!able of weighing to M 1 g.
2. != eter with electrode <. =ot !late 4. <00 l vessel 6 stainless steel or "yre- beaker ?. Stirrer 6 electric rod iersion ty!e or eAuivalent. J. +atch glass 6 to cover ?00 l vessel. 7. "i!ette 10 l. !eagents; 1. %istilled water 2. ortho "hos!horic acid 8?C <. uffer != 2.? Procedure; 1. ;ccurately weigh 2?0 g 5M1 g* of sa!le sugar into ?00 l beaker. 2. +eigh 2?0 g distilled water into the sae vessel. <. Stir unfilled co!letely dissolved. 4. Standardie the != eter with the 2.?# 4.01# 7.00# 10.01!=. ?. Binse the electrode with distilled water and !lace it into the sugar solution. J. &sing the 10 l !i!ette# add !hos!horic acid dro! wise until the != of The sa!le solution is lowered to 2.0 M 0.1. 7. "lace the sugar solution on the hot !late and heat )ust to boiling. f a vessel is used that is not stainless steel# use a boiling water bath to =eat the solution. ;s soon as if begins to boil# reove the vessel fro The hot !late and cover it with a watch glass. 8. ;llow the solution to reain totally undisturbed for 48 hour. ;fter 48 hours# observe the solution carefully for traces of floc. f floc is !resent# a 3ail ranking is indicated and test ay be sto!!ed. . f no floc is noticed after 48 hours# ake daily observation for the e-t 8 days. f floc for is !resent# a 3ail ranking is indicated. f no floc is evident after a total of 10 days# a 3"ass 3ranking ay e assigned.
Test,% Doreign Matter in Sugar
Purpose; To check sugar sa!le for !resence of foreign atter. #uipment; 1. Faccu filtration a!!aratus ca!able of su!!orting 8.0 icron filter !ads. 2. Faccu filtration flask 1.? 6 2.0 liter ca!acity.
<. 4. ?. J. 7. 8. .
%rying oven %rying dishes #2( aluinu to su!!ort filter dishes in oven =ot !late ;nalytical balance 6 ca!able of weighing to M 0.0001 g. alance 6ca!able of weighing to M 1 g. Stirrer ( electric rod iersion ty!e eaker 6 1 liter and 0.? liter ca!acity.
!eagent6Chemical; %istilled water# !refiltered through 8.0 K filter !ads. Procedure; 1. +eight <00g of distilled# !refiltered water into a ?00 l beaker# and heat )ust to boiling. 2. +eight <00 g of sugar sa!le into the 1000 l beaker. <. +eight ?00 g of distilled# !refiltered water into the sae beaker as the sa!le. 4. Stir until the sugar is co!letely dissolved. ?. ;sseble the filtration a!!aratus with two 8.0 K fitters on to! of each other in the filter assebly. J. =eat the sugar solution )ust to boiling. 7. +ith vaccu# filter the entire hot sa!le solution through the filters. 8. Binse the sa!le beaker with the <00 g of hot water set aside in ste! (1 above . ilter this rinse water through the sae filter as the sa!le. 10. "lace the two filter !ads in aluinu weighing dishes and dry in an oven at 0Q, for ? inutes. 11. Beove the !ads# eAuilibrate to roo te!erature# and weigh each !ad to M0.0001 g. Calculation; irst calculate the difference in wt between the two filter !ads used in the filtration .The 3To! filter !ad should hold all the foreign atter and the 3otto !ad should serve as the 3lank 3having no foreign atter on if t o' 'oreign matter gram < )t o' Top 'ilter pad )t o' Bottom 'ilter pad
Then# calculate the !! of foreign atter in the sugar sa!le as follow
Doreign matter ppm < )t o' 'oreign matter in gm = +>>>(>>> t o' sugar sample used in gm Test 8, Moisture,
;ccording to &@s s!ecification sugar which is used to !roduce ,S% should have the oisture range 0.02 to 0.04 C.. Test 9, Microbial Testing, n icrobial testing of sugar we check the yeast ' old count !resent in 100l sugar solution. ;ccording to &@s s!ecification yeast ' old count should not be ore than 1?. lock Test( ;ccording to &@s s!ecification sugar used in ,S% !re!aration should be !ure. To check the !urity of sugar we use ?0 degree ri- of solution. To aintain "h5!awer of =R* u! to 2 with the hel! of adding 9rtho "hos!horic ;cid. ' than it headed on hot !late after that it stands for 10 days.
Test ,2.- C* - Purity
Purpose; To check the gross !urity of ,92 su!!ly. 1. oh 6negel ,92 !urity test a!!aratus 2. Begulator Procedure; 1. Begulate ,92 flow to less than 10 !si. 2. ;ttach ah 6 negel a!!aratus. <. "urge a!!aratus. 4. ,ollect sa!le. ?. ;dd caustic solution 10 C. J. ubble ,92 through caustic 7. Botate a!!aratus 8. Bead C ,92 !urity above .0 C.
2.0 T#STN1 *D C"#MCA/S +. Derrous Sulphate ?DeSo2@;, S!ecification 1("urity not less than .?C 2(nsoluble atter not ore than 1C. C 5"urity*OT.BP2.78C. -. Acti3ated Carbon 1ranular ; (s!ecification
1($oisture 5a-*(10C 0. Commercial Salt;,speci'ication 1("urity not less than 7.?C on a dry basis. C5"urity*OTBP0.1P.0?844P100/wt. of sa!le. 2. Caustic Soda DlaEes;, s!ecification 1("urity not less than JC. C5!urity*OTBP0.8P100/wt. of sa!le. 4. "C/ ;, s!ecification 1(!urity not less than <1.?C %. "ydrated /ime;, s!ecification 1(!urity(;vailable ,a9OJJC50Cas ,a59=*2* 2(nert aterialOnone C5!urity ,a9*OTBP1.87/wt. of sa!le C5,a59=*2*OC of ,a9P7?/?J 8. Bleaching po)der;, s!ecification 1(;vailable ,l2O70C by weight. C,l2OTBP14.184/wt. of sa!le 9. "y'lo) Super cell ;, s!ecification 1(,olor(light !ink to white 2("= value(105a-* <(oisture(0.?C5a-* 5. Testing o' ater?TP@ =ardness
Softness
;lkalinity
,hlorine
+>. Testing o' 'la3our F Salt Testing of flavour ' salt are !erfored in ,hanno !lant "un)ab.
lavour ade u! of two !arts(
,oncentrate
;cid !art
The forula of concentrate is secret.
The acid !art contains citric acid anhydrous #!otassiu sorbate# alic acid# tartaric acid.
PacEaging materials +. Cartons Test,To easure :ength# +idth# =eight# "rinting# DS$. -. rap around(To easure :ength# +idth# ,enter to ,enter# "rinting# DS$. 0. Closures( To easure +eight# =eight# SST# and "rinting address# ,%F# "9# ,=: no.* 2. Cro)ns(To easure +eight# Do/o Do# "rinting5address# ,%F# ,$%# utritional inforation# ngredients# ,;T(1 ' ,;T(<*# ,orrosion Test# :iner ;dhesion# 4. /abels(To easure ,oil +idth# Be!eat :ength# ,oil %# ,oil 9%# ,ore Thickness Fisually ,heck 5!lant address# nutritional inforation# ingredients# ,;T(1 ' ,;T(<*# DS$ %. Slee3es( To easure ,oil +idth# Be!eat :ength# ,oil %# ,oil 9%# ,ore Thickness Fisually ,heck 5!lant address# nutritional inforation# ingredients# ,;T(1 ' ,;T(<*# DS$. 8. #mpty 1lass Bottles ( To easure +eight# =eight# ase %iaeter# Shoulder %iaeter# riful ,a!acity# and Folue at fill !oint# $ould uber. 9. Pre'orm tests T9 easure =eight( +eight( eck finish( nternal neck diaeter ( -ternal neck diaeter ( "refor diaeter ( Date height( "refor defects in "olarisco!e
AT#! T!#ATM#NT T#ST;,
+.A/&A/NTG ? -P,M @;,
P:!P*S#;, The !ur!ose of the 2"($ or alkalinity test is to verify that the water treatent !lant is o!erating correctly and that the final treated water used for the !rocessing confors to standards. =igh alkalinity in !rocess water will have an undesirable effect on the taste of the finished beverage.
P!NC/A/ *D *P#!AT*N;,
The nuerical value of 2"($ is e-!ressed as 3; 52"($* and indicates whether the hydrated lie dosage# or
e-cess of hydro-ide alkalinity# is correct. ;t the sae tie# the ethod easure L$@ the total alkalinity. The L"@ alkalinity re!resents all of the hydro-ide alkalinity# and one half of the carbonate alkalinity. The alkalinity relationshi! is based on the fact that the bicarbonate and hydro-ide fro cannot co(e-it. There are two a!!roved ethod for easuring the alkalinity of the water. 9ne uses two colorietric indicators# which change the color of the solution under testU this is suitable for o!eration that does not have access to != eter. The other ethod is !referred since it reoves the sub)ectivity of inter!reting a color change and uses a != eter to deterine the test result.
!#AS#NT ;• • • • •
/?0 50.02* Sulfuric acid L"@ indicator 5"henol!hthalein * L$@ indicator 5$ethyl !ur!le* LT@ solution 5Sodiu thiosulfate* %istilled water
+ater sa!le
;dd. "henol!hthalein indicator
Titrate 0.02 =2S94
"ink to colorless end !oint
Becord l 0.02 =2S94 L"@ reading
;dd. $ethyl !ur!le
,ontinue titration
,olor change fro green to !ur!le
Becord total 0.02 =2S94 usage L$@ reading
-."A!$N#SS ?CA/C:M F T*TA/@;, P:!P*S#;, +ater hardness is treated for at least two reasons E( •
•
n !lant where sodiu alkalinity is !resent# to onitor the effectiveness of coagulation syste by gauging the need for addition of a calciu salt to the reaction tank# +here water is softened to deonstrate the effectiveness of the softening !rocess.
P!NCPA/ *D *P#!AT*N;,
=ardness in water is caused by dissolved inerals# !riary those !roducing divalent or double charged# cations including calciu 5,a2R*#$agnesiu 5$g2R*#ron 5e2R*#Strontiu5Sr2R*#inc5n2R*# ' $anganese 5$n2R*. ,alciu ' $agnesiu ions are usually the only one !resent in significant concentration in ost watersU therefore hardness is generally considered by our industry and by the unici!al water treatent industry to be a easure to be a easure of the calciu and agnesiu contact of water.
TGP# *D "A!$N#SS;Temporary or carbonate hardness;,
t is the hardness due to the bicarbonate of calcium an ma!ne"ium in the raw water. y classical definition# this ty!e of hardness can be reoved by boiling the water. n the soft drink industry# te!orary hardness is reoved by the cold lie treatent that also reduces the alkalinity at the sae tie. ,a5=,9<*2 R ,a 59=*2
2,a,9< R 2=29
$g5=,9<*2 R2,a59=*2
2,a ,o< R$g59=*2 R 2=29
Carbonate or non, carbonate hardness;, t is the due to the c#lorie an "ulfate of the calciu and agnesiu in the raw water. This hardness cannot reoved by the boiling the water. This ty!e of hardness is not reoved by the cold lie !rocess. To reove this hardness with a Lconventional@ syste# soda ash 5a2,9<*ust be added to the water. This then fors the calciu and agnesiu carbonates# as the reaction below illustrates# which !reci!itate in the reaction tank.
,a,:2Ra2,9<
,a,9< R 2a,:
#DD#CT *D "A!$N#SS *N S*DT $!N&;,
,alciu hardness# when !resent in oderate aounts 5:ess than 70!!.* does not adversely affect traditional soft drinks. 5or e-a!le. "e!si# 7&"# 9range.*There fore no s!ecial effort +ater used for sanitation !ur!oses should be fro a sanitary su!!ly. f the water is for a unici!al su!!ly with good Auality characteristics and eets sanitary criteria# it can be used for without further treatent for other Sanitation !rogras. f the !lant water su!!ly tests !ositive for colifor or contain any other dangerous organis# this su!!ly cannot be used in the sanitation !rocess. f the water is for an acce!table water su!!ly and taste negative for colifor# then si!le chlorination is sufficient# aintaining a!!ro-iately 0.2!! free available chlorine at the outlet. n "e!si ,o. ndia =oldings "vt. :td.# a!ur# the three ty!es of water used E ( •
•
• • •
Baw water Soft water Treated water
+e use raw water for storage !ur!ose# drinking# canteen use etc. Soft water used for cooling tower# bottle washer and boiler. Treated water used for syru! and beverage aking. Baw water is !u!ed u! by bore well ' !ut to various treatent to obtain Treated !a) )ater # having hardness due to ,aRR ' $gR ions is softened with the hel! of sodiu eolite. +hich act as a softner. t absorb all hardness !resent in the water it is the re!laced !eriodically after use. So't )ater is ainly used for washing !ur!ose. it is also used in boiler and refrigeration e!ty bottles ' eAui!ent are washed using soft water.
Quality test 'or Carbonated so't $rinEs ?CS$@
Test.+ 1as Holume Testing
*bIecti3e; To check Das volue 5,92* !resent in bottle. #uipment; 1. ah nagel hand shake tester. 2. Terries ake calibrated !ressure gauge <. Terries ake calibrated dial theroeter
4. "e!si ,92 scale. Procedure; 1. Ferify the calibration status of the !ressure gauge and %ial theroeter. 2. Sa!le selection and !re!aration 2.1 for line check select crowned bottle with fill height to ??(J0 . Auilibrate by gently inverting the bottle for 20 ties in <0 seconds. 2.2. for trade sa!le# ware house sa!le and beverage shelf life sa!le. ,hill the !roduct to ?R(10deg., and eAuilibrate by gently inverting 10 ties in 1? seconds. <. ;fter eAuilibrating# wait for the bubbles to clear the liAuid. 4. ,over bottle with leather safety ground. ?. "lace the sa!le bottle under the tester and align crown or closure with the !iercing device. J. ,lose the snift valve at the front of the tester. 7. Dri! lack s!ring and carefully lower the cross bar until the sealing ring or !iercing needle rest on the crown. 8. "ierce the crown by forcing the cross bar down with a fir ra!id otion. . Belease the lock s!rings. 10. "ush the theroeter into the bottle before it touches the beverage. 11. Belease head !ressure by carefully o!ening the sniff valve. 12. ,lose the valve as the head !ressure reaches 2 !si. 1<. "ush the theroeter into the bottle as for it can go. 14. =old the botto and the tester !ad in one hand and the cross bar in the other. Shake the tester vigorously in a horiontal otion until the !ressure gauge reads a constant a-iu !ressure. 1?. Becord the constant !ressure and te!erature. 1J. ,onvert !ressure and te!erature togas volue using "e!si ,92 wheel. 17. efore reoving the bottle fro the tester# o!en the snift valve and vent until !ressure reaches ero. Note; t is pre'erable to use g3 shaEer to bring more accuracy and uni'ormity in testing.
Test.- Bri o' CS$
ri-E t is the aount sucrose !resent in solution. 1 V bri- eans 1 gra of sugar in 100 gras of water. t is easured by refractoeter. *bIecti3e; To check the aount of sucrose !resent in the !roduct. #uipment, 1. 2?0 l glass cylinder 2. Befractoeter <. <00 l stainless steel breaker 4. %ro!!er ?. Tissue !a!er Procedure; 1. Sample preparation 1.1 or sa!le syru!# finished syru! and control drink take sa!le directly. 1.2 or carbonated beverage degas the sa!le. 2. ,lean refractoeter !ris with distilled water and wi!e it dry with tissue !a!er. <. &sing a cleaned and dried eye dro!!er !lace a dro! of distilled water on the !ris surface so as to cover it fully# close !ris cover and !ress LB;%@ key. 4. f reading is showing 0.00R(0.01 then !roceed with the easureent. 1. +i!e the water fro the !ris dry and !lace a dro! of the testing sa!le# so as to cover the !ris avoid gas bubbles by degassing the sa!le !rior to testing if reAuired. J. ,lose the !ris cover and !ress LB;%@ key. 7. 9nce the dis!lay stabilies on the screen it is desirable to take another confiratory reading by !ressing the LB;%@ key again. 8. Becord result.
actors that have direct effect on bri- areE W
;ccurate calibration of finished syru! tank 5once a year*
W
;ccurate easureent of si!le syru! volue.
W
;ccurate easureent of si!le syru! bri-.
W
,alculation of sugar content 5to be aintained as !er beverage docuent*.
W
,oncentrate addition under su!ervision of cheist.
W
;ccurate easureent of finished syru! bri- and volue.
W
,alibration of hydroeter for syru! bri- every week.
W
,ontrol drink bri-/ inverted bri-/ T; to be checked to ensure Auality of syru!
Note; everage bri- at ties found out of target at start u!# during batch change over and at the end. !easons;
1. So! not established/ standardied or not being followed rigidly. 2. :ack of knowledge of cheist/ o!erator to o!erate i- !rocessor. <. Syru! line not flushed !ro!erly before taking syru! leading to dilution of syru! in the initial stage. 4. ,o2 !ushing is not used to flush water. ?. $i- !rocessor and filler are not flushed with sufficient beverage 510 !si co2 !ressure to be used for flushing*. J. ;ir entra!ent in the syru! during batch change and end !roduction leading to low bri-. 7. +ater being used in soe !lants to !ush syru! instead of co2. 8. $ishandling of refractoeter.
Test0. n3erted bri t is the easure of sugar inversion i.e. nversion of sucrose into glucose and fructose. W
%egas the beverage as !er the degassing study.
W
,lean ' rinse the bottle !ro!erly.
W
Take
W
;dd 0.4 l of 2.? =,l in the sa!le.
W
Seal the bottle !ro!erly and i- the beverage.
W
Gee! the bottle in boiling water for 40 inutes.5tie starts only when the water starts boiling*.
W
,ool it to 20 c.
W
,heck bri- as !er so!.
W
;dd correction factor based on the flavor as !er the beverage docuent.
Test 2. Control drinE
Aim; ; control drink is an individual drink ade by hand. ; control drink ay be ade with treated water to find out what the line beverage target for titratable acidity or bri- should be and if the taste of the finished beverage is acce!table. !eagent6 Chemical; syru! and treated water Process Dlo) $iagram;
;cAuire well i-ed syru! sa!le $i- syru! and treated water in 1E? ration in a ,% flaskU for irinda ake the ratio 1E4
$i- thoroughly using agnetic stirrer
Test for !=# T; and final bri-
ig 10E flow diagra for ,% aking
!ortant things related to ,ontrol %rinkE W
,ontrol drink to be ade two hours !rior to !roduction and then every 4 hours.
W
:ine target to be based on inverted bri-.
W
Syru! bri- ust also be checked while aking control drink. t gives an idea about the accuracy of control drink.
W
%on@t forget to add 0.4 l of 2.? =,l in flavors e-ce!t "e!si for every
T.A. ?Titrable acidity@ t deterines the acidity level of beverage. t is !erfored by titrating 100 l of degassed beverage against 0.1 a9h till !h 8.7?. Dactors e''ecting T.A areE
W
,alibration of finished syru! tank 5once a year*.
W
Sugar content in si!le syru!.
W
S!illage of concentrate during transfer due to ishandling and leakage in the line.
W
$anual i-ing of salts in buckets leading to s!lashing.
W
:eaking buckets.
W
Becirculation line not !rovided for i-ing of salts.
W
=ydroeter not calibrated.
W
inished syru! bri- not aintained.
W
=igh alkalinity of treated water.
W
Ta reduced by 1 l if alkalinity is ?0 !!. "referably alkalinity to be aintained between 20 ( 2? !!
W
,austic carryover reduces T; by neutraliing acid.
W
ri- variation.
W
Too uch foa on the conveyorE !ossibility of foa entering in the bottle which neutralies the acid.
W
%egassing study not done !ro!erly.
W
alse alar on T; due to i!ro!er degassing of beverage/ norality.
W
0.1 a9= solution not standardied 5range E 0.1 R/( 0.002*
W
$anual !h eter used where the calibration is not guaranteed.
W
Te!erature co!ensated autoatic !h eter to be used.
W
!= eter to be calibrated daily with standard buffer solution and slo!e to be calculated.5slo!e should be between ? ( 10? C*.
W
uffer solution to be ke!t in fridge at 4 c and discarded after 7 days.
W
alse reading of T; due to increase in calciu hardness.5this can be overcoe by 10C tri(!otassiu citrate in "e!si only*.
Test,+ Total $issol3e Solids Purpose; The !ur!ose of this test is to !rovide a ra!id# indirect a!!ro-iation of the T%S in a water sa!le as easured by its electrical conductance. #uipment; ,onductivity eter ( Dlass container ( Theroeter !eagent6Chemical; %istilled water Procedure; 1. "our a!!ro-iately ?0 l of distilled water into the glass container and insert the conductivity cell !robe. 2. $ove the !robe u! and down several ties to wash off any solid# !resent in the cell. <. %iscard the water in container. 4. $easure to te!erature of the sa!le and ad)ust the te!erature correction deal on the conductivity eter. ?. nsert the conductivity !robe and ove it u! and down several ties to ensures eAuilibriu and to dis!lace any large air bubbles tra!!ed at the to! of the cell. J. $easure either the total dissolved solid directly in g/lit or !!. Dormula; T$S mg6lit. < conducti3ity ?micro siemens@ = >.%8?con3ersion 'actor@
Test,- p" Test
Purpose; This ethod will !rovide an overview of != easureent of water. #uipment; != eter# theroeter# 2?0 l beaker ( tissue !a!er. !eagent6Chemical; %istilled water 5for rinsing electrode* Procedure; 1. &se a conditioned != electrode and a calibrated != eter. 2. Turn on != eter. <. Binse the electrode thoroughly with distilled water and dab dry with dis!osable tissues. 4. "our the water to be analyed into a clean beaker. ?. ,arefully !lace in clean# dry stir bar into beaker containing water. J. ;llow != to stabilie and record != to the nearest 0.1 != unit. 7. Binse electrode with distilled water. /ine,2 K1lass lineL
This line !roduces 200l and <00l of reusable glass bottles. This is a very i!ortant segent of !lant. t is also very i!ortant fro Auality !oint of view as it is very !rone to icrobial growth. $ain co!onent of glass line isE ottle washer# filler# ,oding achine and case !acker. %.0.+
Bottle )asher system
mportance o' bottle )asher
W
W W W W
Shelf life of finished !roduct will invariably be reduced ins!ite of using best Auality water# sugar# concentrate etc. f the bottles are not !ro!erly cleaned and sanitied. !ro!er washing of bottles will adversely affect the sensory of the !roduct due to icro containation and old growth. ottle washing !rocess looks very easy. =ence we neglect it. =owever# it is the ost i!ortant area where we have to give our a-iu efforts. orally concerned !ersons feel that bottles feeded in bottle washer will autoatically get cleaned without caring for the o!eration of the bottle washer.
Be'ore bottle )asher( remo3e the 'ollo)ings 1. Fery dirty/containated/old infested e!ty bottle 5grou! < bottles*. 2. ull crates if dirty e!ties are high in nubers 5around 8( bottles*. <. Straw/ rusty neck.
4. $i- brand bottles. ?. 9ther brand crates. J. ,hi! neck bottles. 7. ottles having !ouches# insects etc. 8. +hole !allet to be re)ected if e-cessive dirty bottles are visible Single line ins!ection is the ost effective answer. The components o' bottle )asher are; a* "re rinse segentE W t is the ost i!ortant stage of washing which is neglected. W t reove loose dirt and other foreign atter. W t avoids carryover of dirt into caustic tanks. W Het !ressureE in 2 kg/c2
b* irst soak E W To loosen ' reove sticky aterial# dirt. W To !re heat the bottles. "araeters W ,austic strenghtE 1.?(2.0 C W Te!eratureE ?0(?? c
c* "re wash W To reove dirt ' sticky aterial# this is loosened in !re soak. W Het !ressureE min - Eg6cm"araeters W ,austic strengthE 1.?(2.0 C W Te!eratureE ??(J0 c d* $ain soak ; "ur!oseE To clean and sanitie the bottles "araeters W ,austic strengthE 2.?(< C W Te!eratureE 72(77 c W Su 2J0 !E 800(1000 !! W Soak tie E 7.? inutes W ,arbonatesE X 1 C oteE Therostat should be !rovided to control the te!erature within the recoended range. Caustic;
;dvantage W ,austic has gericidal action. W ,austic is a good cleaning agent. %isadvantages W ,austic alone is not effective. W t cannot !enetrate W t enhances scale foration due to foration of carbonates. W t attacks the bottle surface. Additi3e ?su@ W t enhances the cleaning affect. W t softness old !ads ' dirt in the bottles. W t increases rinsibility of caustic solution. W t !revents scale foration. W =el!s to settle !articulate atters. =ence caustic soda with su(2J0 5as recoended by !fl* to be used. "ydro spray; W To reove caustic residue. W To reove dissolved/ sus!ended dirt fro bottles To reduce te!erature gradually to avoid theral shock
e* "re final rinse E W To reove left over caustic residue. W To further reduce te!erature of the bottles. W Beoval of caustic trance and cooling of bottle 5 1 to 2 !! cl2*. f* inal rinse E W ottles washed with soft water with 1.0 !! free chlorine. W +ater should be free fro any !articles. W Beoves caustic residue fully. W g* 9ut feed E t receive bottle fro carrier and guides to the conveyor.
Dlo) diagram o' bottle )asher system ottle feed
"re Binse
irst Soak
,austic 1.? C ;t ?? deg ,
C
,austic 2.?
$ain Soak
;t 70 deg ,
Soft water
=ydro S!ray
,austic X 1.? C
"re inal Binse inal Binse
ottle 9ut
ig 1
%.0.- Test n 1lass /ine Test,+ Caustic Strength Aim; To heck the concentration of caustic in solution of !re and ain soak. #uipment; 1. 10 l urette 2. 10 l !i!ette <. 10 l easuring cylinder 4. 1?0 l conical flask ?. ?0 l Draduated cylinder !eagents6Chemical; 1. 2.? sulfuric acid 2. 10 C ariu chloride solution <. "heno!thalein indicator solution 4. %istilled +ater Procedure; 1. 9!en the sa!le cock of bottle washers and discard the first 1?0 l and 200 l of caustic solution. 2. ,ollect the caustic sa!le fro bottle washer soak(1 and bottle +asher soak(2 se!arately in a clean and dry glass bottle. <. "i!ette out 10 l of caustic solution and it into 100 l conical flask containing 10 l of distilled water. 4. To this solution and ? l of 10C bariu chloride solution and i- thoroughly. ?. Titrate the solution against 2.? sulfuric acid solutions by using !henol!hthalein indicator# till the !ink color disa!!ears. J. ote the titrate value. 7. ,alculate Lcaustic strength @.
,austic Strength O Titre Falue P Strength of Sulfuric acid P 0.04 P 100 Folue of sa!le Taken +here 0.04 O illi eAuivalent of Sodiu hydro-ide
Test,- Methylene Blue Aim; $ethylene blue test is !erfored to check !resence of olds in bottles. #uipment; 1. ye %ro!!er 2. unnel <. +eighing alance 4. 1000 l Foluetric lask !eagents6 Chemical; 1. $ethylene lue "owder 2. %istilled +ater <. ?C thanol solution 4. Treated +ater Procedure, 1. Methylene Blue Stain Preparation ?>.+@ 1.1 Farity the calibration status of weighing balance. 1.2 +eigh 1g of ethylene blue !owder. 1.< %issolve in ?0 l ?C ethanol solution. 1.4. ;dd ?0 l distilled water and stir to dissolve. 1.?. %ilute to 1000 l with distilled water. 2. Sto! bottle washer. <. ,ollect all ?? bottles fro 1du!/stroke of bottle washer at discharge. 4. "our ethylene blue stain 50.1C* into bottle using funnel. ill u! to 1/
Test,0 Carbonate Test
Aim; ,arbonate test is done to check hardness of water. #uipment; 1. 10 l autoatic burette 2. 10 l !i!ette <. 100 l conical flask !eagent6Chemical; 1. Standardied 2.? sulfuric acid 2. 10C ariu chloride <. "henol!hthalein indicator 4. $ethyl orange indicator ?. %istilled water Procedure; 1. 9!en the sa!le cock of the bottle water and discord the first 1?0 l and 200 l of caustic solution. 2. ,ollect the caustic sa!le fro bottle soak(2# se!arately in a clean and dry glass bottle. <. "i!ette out 10 l of this caustic solution and transfer into 100 l conical flask. 4. To this solution and ? l of 10C bariu chloride solution and i- it thoroughly. ?. Titrate the solution against 2.? n sulfuric acid solution using !henol!hthalein indicator# till the !ink color disa!!ears. J. ote titrate value. 7. ,alculate L"@ value. P 3alue < titrate 3alue 8. ;dd 2 dro!s of ethyl orange indicator to the above solution ;nd continue titration till the color change fro yellow to !ink. . ote titrate value and calculate L$@ value. M 3alue < titrate 3alue 10. ro " and $ value can calculated -?M,P@ !ercent as ,arbonate level. 11. Becord result.
Test,2 Dree S: Test
Aim; To find aount of free S& in solution. #uipment; 1. 1 l graduated !i!ette 2. 10 l !i!ette <. 100 l conical flask 4. 10 l burette !eagent6Chemical; 1. Total hardness indicator 2. 2.? sulfuric acid <. ;onia buffer 4. S& reagent Procedure, 1. Take caustic sa!le fro soak(2 of bottle washer. 2. $easure 2? l of the above sa!le and dilute it with 7? l of distilled water and deterine its strength using 2.? sulfuric acid# record the aount of titrant consued. <. "i!ette out another 2? l of the sa!le and 7? l distilled water. 4. ;dd the e-act aount of 2.? sulfuric acid as deterined fro stee!(2. ?. ;dd < dro!s of aonia buffer solution. J. ;dd !inch of total hardness indicator and swirl gently. 7. ;!!earance of wine red or violet color indicates absence of free S& 2J0. 8. ;!!earance of blue color indicates !resence of free S&2J0. . n case of !resence of free S& 2J0# titrate the sa!le with S& reagent till the a!!earance of violet or red color. 10. Becord the Auantity of S& reagent consued say LY@ l. 11. ,alculation ppm o' 'ree S: -%> < 7 ml = 028>
Test,4 $i3o /#,Chemical Test AM; To check aount of free : in washing solution. #uipment; 1. 1 l Draduated !i!ette 2. 10 l !i!ette <. 100 l conical flask 4. 10 l urette !eagent6Chemical; 1. rochroe black T indicator 2. ;onia buffer <. %ivo reagent 4. Total hardness indicator Procedure; 1. %raw water sa!le coing fro !re final )et of bottle washer. 2. $easure 100 l the above sa!le. <. ;dd < dro!s of aonia buffer solution. 4. ;dd one !allets of total hardness indicator and swirl gently. ?. ;!!earance of blue color indicates !resence of free %ivo le. J. n case of !resence of free %ivo leU titrate the sa!le with %ivo le reagent# till the a!!earance of violet or red color. 7. Becord the Auantity of %ivo le reagent consued say LY@ l. 8. ,alculation ppm o' 'ree $i3o /e < 7 ml = 54
Test,% Cro)n Crimping AM; To check crowning of bottles. #uipment; ,alibrated LDo(o Do@ cri!ing gauge. Procedure; 1. ,ollect filled bottle fro each crowner need. 2. "lace the bottle on a level surface. <. &se LDo@ a!erture L1.1
Test,8 Bottle ashing Caustic Carry *3er Presence o' Caustic in bottle can; 1. ,ause and off taste in the !roduct 2. ;ffect the crown or closure. <. ,ourse the bottle to look dull instead of clean and clear. Purpose; To confir the absence of caustic in container that have been washed and rinsed. ; bottle out transfer tank with caustic carryover is not considered clean. #uipment; ye dro!!er or sAuirt bottle. !eagent6Chemical E "henol!hthalein indicator Procedure; 1. ;dd <(4 dro!s of "henol!hthalein indicator to neck of bottle. Botate bottle for even distribution of indicator. 2. ;dd ?(J dro!s of "henol!hthalein indicator to li! of bottle and outside neck area# rotating bottle for even distribution. <. ;ny red/!ink color indicates caustic carryover. 4. Becord and re!ort out coe and action.
Test,9 Dill "eight Aim; To easure fill height. #uipment; ,alibrated fill height gauge Procedure; 1. ,ollect to crowned bottle corres!onding to filling valves of the filler fro the !roduction line. 2. Set he bottle on a level surface rest the to! bar of the gauge on the crown in a level !osition. <. Slide the !ointer until the to! of the caliber coincides with the lower eniscus of the liAuid level. 4. Bead the ark on the scale. ?. Becord result.
Test,++ Net Contents Aim; The bottle has a legal and ethical obligation to !rovide the consuer with the aount of !roduct declared on the !ackage. #uipment ( 1. lectronic balance with <000 gras ca!acity and 0.1 g accuracy. 2. %rainage rack Procedure( 1. ;cAuire a filled and sealed bottle. 2. nsure the outside is dry and clean. <. +eight the full bottle and record the weight. 4. ,o!letely drain the bottle in drainage rack# about <0 seconds. ?. Becord the weight of the e!ty bottle. nclude !ull tab fro crown. J. ,alculate the net content weight in gras fro the following eAuation. Net content ?gm@ < )t 'ull bottle ?)t empty bottleO cro)n@
Test,+0 Candling Dor Doregn Material Aim; This ethod is intended to identity foreign aterials in bottle beverages via candling observation with follow u! confiration of sus!ected !ositive by filtration. #uipment E 1. <00 watt !ro)ection la! with a <0(40 lens. 2. Bing stand or other holder for inverting bottle. <. $illi!ore filtration syste with ?K filter !ro!er for large !articulates 0.4?K filtration for sall !articulates. 4. inocular icrosco!e Procedure, 1. =old bottle in front of light soure and gently agitate. f floc or any other foreign substance is observed# ark the container and set it aside for confiratory filtration or further testing. 2. nvert the bottle and iediately !lace if in the holder a!!ro-iately one inch fro the light source# slightly off center. <. 9bserve the neck area above the closure or crown for at least <0 seconds watching for foreign aterial entering these areas. Scan the reainder of the container for sus!ended or floating aterials ( Dlass falls directly# reflects and refracts light ( iber floats and is translucent to light ( ,92 bubble vary in sie# floats# drifts u! and down# trans!arent to light ( "lastic# organic growth and cellulose will float# sus!end# or fall 4. $ark and set aside those containers with !resu!tive foreign aterial finding. ?. ilter all sus!ect !roducts reaining after necessary analytical sa!le have been reoved. J. $icrosco!ically observe filter !ads and identify any confired foreign aterials.
