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Report title:
Internship at Riaz Bottlers (Private) Ltd.
PEPSI-COLA BOTTLERS.
Submitted by:
Sabih ul Hassan
Roll # 39
B.Sc. (Hons.) Food Science and Technology
Semester 8th (Self Support)
Subject:
Internship Report Writing
FST-611
Submitted to:
Dr. Tahir Mehmood Qureshi
Assistant Professor
Institute of Food Science and Nutrition (IFSN)
University of Sargodha, Sargodha
INSTITUTE OF FOOD SCIENCE AND NUTRITION
UNIVERSITY OF SARGODHA, SARGODHA
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ACKNOWLEDGMENTS
“In the Name of ALLAH, the most Beneficent the most Merciful”
I am thankful to the most gracious and merciful "Almighty Allah" who gave me health, thoughts
and opportunity to complete this work. Our compassionate Hazrat Muhammad (Peace be upon
him) who is ever a torch of guidance and knowledge for humanity as a whole.
I would like to express my deep gratitude to kindhearted Prof. Dr. Sarfaraz Hussain , Director,
Institute of Food Science and Technology, University of Sargodha, Sargodha, and MR Tahir
Jaleel Khawaja (GM PLANT, RIAZ BOTTLERS PVT. Ltd) who gave me an opportunity of
internship in an Riaz Bottler (Pepsi Cola) Lahore.
I have the honor to express my deep senses of gratitude that this internship has found its way to a
successful completion due to kind supervision of Mr Ijaz Ashiq, General Manager Quality RBL
inspiring guidance, valuable suggestions and sympathetic attitude of Mr. Muhammad Sarfaraz,
Quality Assurance Manager and Mr. Naveed Ahmed, Quality control manager. My grateful
thanks are also extended to Mr. Javed Akhtar, Riaz Bottler Lahore for their kind attitude and
help to accomplish my work successfully.
I would also like to extend my thanks to the respected analysts of the laboratory of respective
departments for their help and supervision during my working period.
Finally, I wish to thank my Parents, Teachers and Friends for their support and encouragement
that made me able to achieve this goal.
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Contents 1 PEPSI COLA INTERNATIONAL (PCI) ................................................................................ 7
1.1 HISTORY OF PEPSI COLA ........................................................................................... 7
1.2 PEPSI COLA INTERNATIONAL IN PAKISTAN ........................................................ 7
1.3 Introduction to rbl history ................................................................................................ 8
1.4 Company objectives ......................................................................................................... 8
1.5 CORE VALUES .............................................................................................................. 9
1.6 AWARDS......................................................................................................................... 9
1.7 SKU .................................................................................................................................. 9
1.8 Pepsi ................................................................................................................................. 9
1.9 7up .................................................................................................................................... 9
1.10 Dew ............................................................................................................................. 10
1.11 Marinda ....................................................................................................................... 10
1.12 Sting ............................................................................................................................ 10
1.13 Pepsi Diet .................................................................................................................... 10
1.14 7up diet ....................................................................................................................... 10
1.15 Aquafina ..................................................................................................................... 10
1.16 Slice ............................................................................................................................ 10
2 OVERALL PROCESS LAYOUT ......................................................................................... 11
2.1 FUNCTIONS OF WATER ............................................................................................ 11
3 WATER TREATMENT ........................................................................................................ 12
3.1 OBJECTIVES OF WATER TREATMENT .................................................................. 12
3.2 pROBLEMS IF STANDARDS ARE NOT MAINTAINED ......................................... 12
3.3 IF SOLIDS (IMPURITIES) ARE MORE THEN .......................................................... 12
3.4 WATER STANDARDS FOR PEPSI COLA PRODUCTS ........................................... 12
3.5 TYPES OF WATER ...................................................................................................... 13
3.6 WATER TREATMENT SYSTEMS ............................................................................. 13
3.7 ion exchange method ...................................................................................................... 13
3.8 Water softner unit ........................................................................................................... 13
3.9 Purpose for using ionexchange method ......................................................................... 14
3.10 COAGULATION SYSTEM ...................................................................................... 14
3.11 purpose of using coagulation water treatment ............................................................ 14
4 SUGAR DISSOLVING ......................................................................................................... 15
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4.1 BATCH PROCESS ........................................................................................................ 15
4.2 CONTINUOUS PROCESS............................................................................................ 15
4.3 SUGAR BUNKER ......................................................................................................... 15
4.4 Initial syrup storage tank ................................................................................................ 16
4.5 Final syrup storage tank ................................................................................................. 16
4.6 MIXING ......................................................................................................................... 16
5 SYRUP ROOM ..................................................................................................................... 16
6 BEVERAGE PROCESS IN AREA ...................................................................................... 17
6.1 Glass line (RGB Line) .................................................................................................... 17
6.2 PET Bottle line ............................................................................................................... 17
7 ANALYTICAL LAB ............................................................................................................ 20
7.1 SUGAR QUALITY TEST ............................................................................................. 20
7.2 caustic carry over test ..................................................................................................... 21
7.3 MOLD TEST.................................................................................................................. 21
7.4 TEST FOR SYRUP AND FINISHED BBEVERAGE .................................................. 22
7.5 BRIX BY DENSITOMETER ........................................................................................ 23
7.6 BRIX INVERSION TEST ............................................................................................. 23
7.7 TITRATEABLE ACIDITY (fOR cola drinks) .............................................................. 24
7.8 net contents ..................................................................................................................... 24
7.9 DEGASSING OF BEVERAGE ..................................................................................... 25
7.10 TEST FOR GAS VOLUME ....................................................................................... 25
7.11 TORQUE TESTING .................................................................................................. 25
7.12 SECURED SEAL TESTING ..................................................................................... 26
7.13 TASTE, ODOR AND APPEARANCE TEST ........................................................... 26
7.14 PH TESTING ............................................................................................................. 27
8 AQUAFINA SECTION ........................................................................................................ 27
8.1 Mineralization ................................................................................................................ 27
8.2 Salts ................................................................................................................................ 28
8.3 Batching procedure ( for 10 mins ) ................................................................................ 29
8.4 1 µM FILTER ................................................................................................................ 29
8.5 PRODUCT TANK OR OZONATION .......................................................................... 29
8.6 RINSING TANK............................................................................................................ 29
8.7 rinsing ............................................................................................................................. 29
8.8 FILLING OF WATER ................................................................................................... 29
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8.9 NITROGEN INJECTION .............................................................................................. 30
8.10 CAPPING ................................................................................................................... 30
8.11 NECK SLEEVE ......................................................................................................... 30
8.12 BLOWING OF PACKED PET BOTTLES................................................................ 30
8.13 STACKING ................................................................................................................ 30
9 AQUAFINA ANALYTICAL LAB....................................................................................... 30
9.1 INSTRUMENTS USED IN AQUA FINA ANALYTICAL LAB ................................ 31
9.2 pH Meter ........................................................................................................................ 31
9.3 conductivity meter .......................................................................................................... 31
9.4 torque tester .................................................................................................................... 32
9.5 ozone comparator ........................................................................................................... 32
9.6 net content ...................................................................................................................... 33
9.7 fill height ........................................................................................................................ 33
10 MICROBIOLOGY SECTION........................................................................................... 34
10.1 external cip ................................................................................................................. 34
10.2 internal cip .................................................................................................................. 34
10.3 Sanitizing agents ......................................................................................................... 34
10.4 3 TYPES OF INTERNAL CIP EXPLAINED ........................................................... 35
11 SLICE TETRA PLANT ..................................................................................................... 35
11.1 Creasing unit ............................................................................................................... 35
11.2 SA (Seal Test) ............................................................................................................. 36
11.3 Filer Bath .................................................................................................................... 36
11.4 Aseptic Chamber(Squeeze ruler) ................................................................................ 36
11.5 Air knife:..................................................................................................................... 36
11.6 Packet Shape ............................................................................................................... 36
11.7 Final Folder Unit ........................................................................................................ 36
11.8 Three values of machine ............................................................................................. 36
11.9 Valve A: ...................................................................................................................... 36
11.10 Valve B: ...................................................................................................................... 36
11.11 Valve C: ...................................................................................................................... 36
11.12 Mixing Process (Steps): .............................................................................................. 36
11.13 Slice Lab Test: ............................................................................................................ 36
11.14 Production ................................................................................................................... 37
12 RBL LAB Instruments ....................................................................................................... 37
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12.1 Degasser Assembly..................................................................................................... 37
12.2 Secure Seal Test .......................................................................................................... 37
12.3 Carbo QC .................................................................................................................... 37
12.4 Hot Air Oven .............................................................................................................. 37
12.5 Refracto Meter ............................................................................................................ 37
12.6 Density Meter ............................................................................................................. 37
12.7 Spectectro Photo Meter .............................................................................................. 37
12.8 De-aerator ................................................................................................................... 37
12.9 Hot Plate titrate ........................................................................................................... 37
12.10 Torque Test ................................................................................................................. 37
12.11 Dew Time ................................................................................................................... 37
12.12 T.A .............................................................................................................................. 38
13 CONCLUSION .................................................................................................................. 38
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1 PEPSI COLA INTERNATIONAL (PCI) 1.1 HISTORY OF PEPSI COLA
Pepsi cola started in Jan 1898, from a small drug store in the city of North Carolina. The owner
of the drug store, a chemist, Mr. Caleb Brad ham, prepared a soft drink whom he was trying to
make it since 1893, the customer called it’ The Brad Drink’. Brad registers this drink with the
name of Pepsi Cola. Then he started his own production at macro level and established his own
company. In 1909 this company reached to 24 states of America with more than 250 dealers.
The very first packing of Pepsi Cola was in 16.5 ounce.
In 1932 Pepsi Cola has introduced its new packing in 12 ounce. In 1950 Pepsi Cola has started its
new advertising campaign with the name of ‘Refresh without Filling’. It also changed the
chemical formula and decreased its sweetness and calories.
With the efforts of sales and marketing department, Pepsi got so much fame that it established
new plants at a rate of thirty per annum.
Caleb Bradham of New Bern, North Carolina was a pharmacist. Like many pharmacists at the
turn of the century he had a soda fountain in his drugstore, where he served his customers
refreshing drinks, that he created himself. His most popular beverage was something he called
"Brad's drink" made of carbonated water, sugar, vanilla, rare oils, and pepsin and cola nuts.
1.2 PEPSI COLA INTERNATIONAL IN PAKISTAN
Pepsi Cola International has given franchise to different bottlers. These bottlers provide
services throughout the world. In Pakistan, the cities in which these bottlers providing services
are following:
1. Lahore
2. Sukkur
3. Karachi
4. Multan
5. Peshawar
6. Islamabad
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7. Faisalabad
8. Quetta
9. Hyderabad
10. Gujranwala
1.3 INTRODUCTION TO RBL HISTORY
RBL is providing services of Pepsi Cola International in Lahore. Riaz Bottlers (PVT) Limited (RBL)
incorporated in Pakistan as a private limited company in 1976. RBL has started his production in
1976 with 3 brands (Pepsi, Miranda, and Team). In 2002 they start production of M.Dew. In
2005 they start production of mineral water as a brand name AQUAFINA. In 2007 7UP
production has started. In 2010 sting production has started. In 2012 they start production of
slice drink (Mango flavor) and in 2014 they add orange and apple flavor in Slice drink.
Now, RBL is the franchise holder of Pepsi cola international with brands like:
1. PEPSI
2. PEPSI DIET
3. 7UP
4. 7UP FREE
5. MIRINDA
6. MOUNTAIN DEW
7. STING (BERRY BLAST
8. GOLD RUSH)
9. AQUAFINA MINERAL WATER
10. SLICE Juice DRINK (APPLE, ORNGE and MANGO)
1.4 COMPANY OBJECTIVES
RBL today is one of the best National Companies in Pakistan. The main objective of company is
to provide customer satisfaction. Therefore, there is no compromise for quality point of view by
following the national and international standards. At RBL, we believe that our existence and
success is more than just meeting our business objectives and we are proud of the success that
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the company has achieved. Together our people provide the skills, knowledge and expertise to
deliver the quality of service that our customers expect and upon which our reputation
depends.
1.5 CORE VALUES
Core Values of Company are as follows:
1. Quality
2. Innovation
3. Team Spirit
4. Mutual Respect
5. Hard work
6. Responsibility
1.6 AWARDS
Following are the awards won by RBL:
1. Pak Ncb Quality Challenge h1-2014
2. Asia PAC Region Quality Award 2014 Sustainable Blue Green Plant
3. Pak Ncb Quality Challenge h2-2014
4. Pak Csd Quality Challenge 2014
1.7 SKU
1.8 PEPSI
250 ml glass bottle
300 ml pet bottle
0.5 litter
1.5 litter
1.75 litter
2.25 litter
1.9 7UP
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250 ml glass bottle
300 ml pet bottle
0.5 litter
1.5 litter
2.25 litter
1.10 DEW
250 ml glass bottle
300 ml pet bottle
0.5 litter
1.5 litter
2.25 litter
1.11 MARINDA
250 ml glass bottle
0.5 litter
1.5 litter
2.25 litter
1.12 STING
250 ml glass bottle
0.5 litter
1.13 PEPSI DIET
0.5 litter
1.5 litter
1.14 7UP DIET
0.5 litter
1.5 litter
1.15 AQUAFINA
0.5 litter
1.5 litter
1.16 SLICE
Mango
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Orange
Apple
2 OVERALL PROCESS LAYOUT
Figure 1
2.1 FUNCTIONS OF WATER
1. Quenches thrust
2. Lubrication of Joints
3. Help in Digestion
4. Medium for chemical reaction to occur
WATER
SUGAR
CONCENTRATE
CO2
MIXING
FILLING
PACKAGING
WAREHOUSING
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5. Maintain Body Temperature
6. Play regulatory Function
3 WATER TREATMENT
Water is the major ingredient of beverage. Pure water contains 11.88% hydrogen and
88.02% oxygen by weight and is odorless, colorless and tasteless. Water is necessity for
human body. Primary function of water is that it carries ingredients of beverage. Water
obtained from ground may contain a high amount of total dissolved solids, high alkalinity,
turbidity, mineral and microorganisms, which may affect the quality of finished beverage.
Water is purified and treated to make it according to required standards.
3.1 OBJECTIVES OF WATER TREATMENT
1. A uniform water supply all the season of year.
2. Removal of colloidal and suspended matter.
3. Reduction in alkalinity.
4. Freedom from microbial hazard.
5. Removal of color.
6. Removal of undesirable off taste and odor.
As water is major constituent of beverage, any difference from water may cause
substantial change in finished beverage. Alkalinity in water can neutralize beverage acid
resulting in lack off tartness or excessive sweat taste and less microbial resistance. Hence
water treatment process is paramount important for quality control of beverage.
3.2 PROBLEMS IF STANDARDS ARE NOT MAINTAINED
1. If alkalinity is the more it will be difficult to set the pH of the beverage product.
2. High microbial growth.
3.3 IF SOLIDS (IMPURITIES) ARE MORE THEN
1. Brackish taste will be percept in the product.
2. Specially if chlorine is more than the product will have a medicinal taste and color
3. of the product will be bleached.
3.4 WATER STANDARDS FOR PEPSI COLA PRODUCTS
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Total Alkalanity 50 ppm
Total Solids 500 ppm
Iron or Maganaese 0.1 mg/L
Copper None
Residual Chlorine None
Odour None
Taste No off Taste
Color None
Turbidity 1.0 ppm
Microorganisms None
These contaminants will overall reduce shelf life of the beverage and cause loss of
carbonation, increase foaming and sedimentation.
3.5 TYPES OF WATER
Four types of water is produced at RBL
1- Raw water
2- Soft water
3- Treated water
4- Aquafina water
3.6 WATER TREATMENT SYSTEMS
Usually two types of systems are used for water purification for carbonated beverage.
1. Water treatment by coagulation
2. Water treatment by ion exchange method.
3.7 ION EXCHANGE METHOD
3.8 WATER SOFTNER UNIT
Water softener contains stones, sand and gravels. They soften the hardness of the water to
zero which is used in washing. Hardness is defined as the property of water which make it
form and insoluble curd with detergent and is due to Ca and Mg. Hardness have no
detrimental effect on health but cause the wastage of detergents, deposition of scales in the
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boiler causing less heat
transfer wastage of fuel and jetting nozzles of washer clogging and cause improper
washing.
There are two types of hardness;
1. Temporary hardness which is due to 𝐶𝑎(𝐻𝑐𝑜)3, 𝑀𝑔 (𝐻𝑐𝑜)3
2. Permanent hardness which is due to 𝐶𝑎𝑆𝑜4 , 𝑀𝑔𝑆𝑜4 and 𝐶𝑎𝐶𝑙2
Zeolite is used for water softening. It is also called green sand or glauconitic. Zeolite can
prepared synthetically and contains Sodium silicate called as permutit. Hard water containing
Ca and Mg is replaced by the Sodium. The system consists of closed cylindrical tank, the upper
part which contains a chamber where dry salt is added at fixed intervals. The lower part
contains a bed of permutit and water simply filters through this bed.
3.9 PURPOSE FOR USING IONEXCHANGE METHOD
It basically provide soft water used for utilities like
1. Rinsing purpose
2. Washing purpose
3. Warming
4. Boiler(fuel in the form of steam)
3.10 COAGULATION SYSTEM
This conventional system consist of raw water entering the reaction tank where it is
mixed with
1. Ferrus sulphate for co-agulation & floc formation CaCl2, needed for sodium alkalinity
reduction.
These equipments can handle most water treatment problems with the exception of
water with high salts and TDS and also difficulty in removing small sized organic molecule.
3.11 PURPOSE OF USING COAGULATION WATER TREATMENT
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METHOD
1. The water which is being obtained by coagulation system has low TDS because in
2. water calcium bicarbonate and magnesium bicarbonate are basic reason for
hardness ,which are removed by using lime.
3. Usage of this system help in reducing alkalinity otherwise this will neutralize the
4. effect of acid which are added in the beverage for taste like phosphoric acid in pepsi.
5. In coagulation system by the usage of chlorine microbes are removed
6. In coagulation system, Filtration of water by sand filter carbon purifier and
7. polisher help in the removal of suspended particles.
8. Water obtained from this system is used as major ingredient in beverage production
4 SUGAR DISSOLVING
There are two types of systems.
1. Batch Process
2. Continuous Process
4.1 BATCH PROCESS
1 batch process contains;
1. Water=5400L
2. Bag of Sugar = 92 bag (4600 kg)
Temperature of water for mixing is maintained at 85oC then sugar is added. This filter
have filter sheet which remove impurities in syrup , filter size 30microns. Flavor /
Concentrate is added at 20oC after cooling syrup by plate and frame heat exchange.
4.2 CONTINUOUS PROCESS
4.3 SUGAR BUNKER
It is made up of stain less steel horizontal conveyor is used for conveying sugar after
crushing it .From the other side water comes which moves toward heat at 60-65 C than it
moves toward dissolving tank.
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5 steps are involved in sugar dissolving process.
1. Dissolving Tank
2. Activated Carbon Tank
3. Filtration
4. Catridge
5. Plate and Frame Heat Exchanger
4.4 INITIAL SYRUP STORAGE TANK
Syrup having 20oC temperature moves to initial syrup storage tank.
4.5 FINAL SYRUP STORAGE TANK
Syrup from initial syrup storage tank moves to final storage syrup tank after mixing with other
ingredient. Brix of Final Syrup varies according to nature of Beverage which is going to be
prepared .Final syrup is prepared for desired beverage by adding color flavor acid preservative
it is also known as Concentrates
4.6 MIXING
The mixing of ingredients in final syrup is confidential.
5 SYRUP ROOM
In syrup room Sugar is added in the treated water which results in the Syrup formation. Later
on Concentrate is also added in it. The mixture is then passed from a Moveable Mixing Tank
resulting in the formation of “Simple Syrup”. That mixture is stored for few minutes and after
some testing the “Final Syrup” is ready for use.
Following is the flow diagram of Syrup Room.
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Figure 2
6 BEVERAGE PROCESS IN AREA
There are 2 types of processing line as given below
6.1 GLASS LINE (RGB LINE)
6.2 PET BOTTLE LINE
Concentrate Treated
Water
Simple Syrup
Movable
Mixing
Tank
Finished
Syrup
Storage
Strainer (OPRP)
Final
Syrup
Pump
s
Strainer (OPRP)
Finished Syrup
Testing
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Figure 3
Syrup
CO2
Treated water
De-
aeration
Tank
Syrup
Tank
Mixer
Filler
Crowning
Checkmate +
Metal
Detector
Date Coding Packer Palletizer
Washer Empty
Inspection
WH Empty
Inspection
(OPRP)
Heat Exchanger
(OPRP)
Strainer
Empty Storage
(OPRP)
Crown
Feeding
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Figure 4
Syrup
CO2
Treated water
De-
aeration
Tank
Syrup
Tank
Mixer
Filler
Capper
Checkmate +
Metal
Detector
Date Coding Warmer
Labeler
Shrink wrap
(OPRP)
Palletizer
Air conveyor
(OPRP)
Rinser
Blow Mold
Heat Exchanger
(OPRP)
Strainer
Preform
Storage
(OPRP)
Cap Feeding
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7 ANALYTICAL LAB
7.1 SUGAR QUALITY TEST
TEST FOR COLOR AND TURBIDITY IN GRANULAR SUGAR
PURPOSE:
Sugar color and turbidity is key indicator of sugar sensory performance in beverage.
Sugar colorants are comprised of plant material and heat degradation while turbidity
refers to soluble lime salt and polysaccharide.
PROCEDURE:
Figure 5
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RANGES FOR COLOR AND TURBIDITY
Turbidity should be =less than 45
Color range should be=less than 45
7.2 CAUSTIC CARRY OVER TEST
PURPOSE:
1. To confirm the absence of caustic solution in container that have been washed and
2. rinsed
3. A bottle or transfer tank with caustic carry over is not considered clean
4. Caustic can cause Off taste in product
5. Affect the crown closure
6. Cause bottle to look dull or firm when dried
PROCEDURE:
1. Add 3-4 drops of P-Indicator to inside neck
2. Rotate the bottle and add 5-6 Drops of Indicator to outside neck then again rotate it.
3. Note the color changes if it changes then corrective action should be taken
otherwise no appearance of color changes shows absence of caustic
7.3 MOLD TEST
PURPOSE:
To check the presence of Mold and other organic contamination, as an indicator of proper
washing operation.
This test is referred to as MBAS (Methylene Blue Active Substance)
PROCEDURE:
1. Collect sample
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2. Fill bottle to 1/3 with Methylene Blue)
3. Rotate bottle to spread stain over entire surface
4. Pour off access stain
5. Rinse bottle after 5 minutes
6. After rinsing if blue color appear on entire inside the surface it will shows the
7. presence of Mold.
7.4 TEST FOR SYRUP AND FINISHED BBEVERAGE
There are two test which are performed after finished syrup formation C.D (controlled
drink formulation is done in a proper ratio)
1. PEPSI = 1:5
2. 7UP =1:5
3. Mt. Dew =1:5
4. Miranda =1:4
5. Sting =1:3
It shows one part of syrup and 4 or 5 parts treated water which are mixed according to
Given ratio. Two test which are performed final syrup is titrate able acidity and brix. The
formula for formulating of controlled drink can be given as:
C.D= Density of finished syrup*Flask capacity/mixing ratio of beverage
PROCEDURE:
1. Take some volume of finished syrup in a beaker
2. Rinse densitometer with finished syrup with the help of injection
3. Take finshed syrup in an injection and inject it in the Densitometer
4. Press the start button
5. Note the density of syrup after some times
6. Put the values in the formula
7. Measure the Beix and TA for final calculation for formation of product
FORMULA:
C.D= Density of finished syrup*Flask capacity/mixing ratio of beverage
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7.5 BRIX BY DENSITOMETER
PRINCIPLE:
Densitometer is the equipment to use for determination of brix and it works on the
following principal. It has a tube in it in which when sample is injected, it vibrates. If sample
Is dense then vibration of tube will be less. And if then density of sample is less it vibrates
rapidly. This equipment shows result in form of brix by converting density into brix
PURPOSE:
It is done to check are measure by weight the percent sold in sample syrup, finished
Syrup controlled drink and final beverage
PROCEDURE:
Take sample of finished syrup mix in proper ratio then stir it for proper mixing after
That removes gas bubble and manually injects syrup sample or C.D to densitometer for
Brix checking
7.6 BRIX INVERSION TEST
PURPOSE:
This test is performed to check brix inversion because sucrose (sugar) degrades into
glucose and fructose which ultimately increase sugar level. Because of this test we set brix
up to a level by keeping brix in a range to avoid any change in quality
PROCEDURE:
1. Take 30ml sample of beverage
2. Then degassed it.
3. Take this sample in a tube
4. Add concentrated HCL drops (3)
5. Then sealed it and cover it with aluminum file
6. Place this tube in water bath having 1000C temperature for 45 minutes. Ultimately
7. sugar will be inverted finally check brix inversion by densitometer
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7.7 TITRATEABLE ACIDITY (FOR COLA DRINKS)
PROCEDURE:
We take 100 ml sample in a beaker and then we will put 2ml TPC (Tri Potassium Citrate) in it to
neutralize Phosphoric Acid in it. Then we will stir it and check its ph. After that we will titrate it
with 0.1 N (NaOH) until its ph reaches to 8.75 (Target). We will note down the reading and then
multiply it by the factor.
In other drinks excluding cola drinks we don’t use TPC.
7.8 NET CONTENTS
PRINCIPLE:
Weigh the beverage in the bottle and note reading. Do empty the filled bottle and weigh it and note reading. Put the values in software and note the net contents.
PURPOSE:
To determine net content of finished product by weights measurement
PROCEDURE:
Acquire full sample
↓
Clean and dry bottle from outside
↓
Weigh bottle with beverage
↓
Empty, rinse and dry the bottle
↓
Weigh the empty bottle
↓
Put values in software and determine the net content of beverage
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FORMULAS:
Net content = Gross weight – empty Package weight – CO2 weight / Density of sample Weight of CO2 = Size of Package (250ml) X gas volume (sample) X 0.00196 7.9 DEGASSING OF BEVERAGE
PURPOSE:
Purpose of degassing is to remove carbonation from beverage sample in order to
obtain accurate brix and T.A
PROCEDURE:
1. Collect sample and warm to 20 – 25 C
2. Turn on air and insert tube or diffuser
3. Bubble air through sample for optimum time
4. Remove sample and turn of air
5. Test for brix and T.A
7.10 TEST FOR GAS VOLUME
In beverage volume of gas is checked by Carbo Q.C PROCEDURE:
1. This equipment is run by using air pressure at 85 – 90 Psi
2. First of all acquire sample
3. Fit in machine
4. Insert tube for creating air pressure
5. Close the container
7.11 TORQUE TESTING
PURPOSE:
To measure the force required to open the closure.
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PROCEDURE:
1. Zero display
2. Turn closure counters clockwise
3. Record removal torque
4. Turn closure clockwise rotate 60 beyond original position
5. Record incremental torque
6. Check against specification
Incremental torque = force released to move closure 60 beyond original position
7.12 SECURED SEAL TESTING
PRINCIPLE:
This test is performed by inducing gas at a controlled rate and time into the head space of
bottle which is inserted in water bath.
No sign of gas leakage will be insured by absence of bubble. It shows that seal is properly
Sealed.
PROCEDURE:
1. Cut approximately 1/8 below neck support
2. Insert cut of the pet in the assembly and then put into sealed water bath
3. Apply the pressure 150 – 175 Psi for 1 -2 Mins.
4. Note gas bubble
7.13 TASTE, ODOR AND APPEARANCE TEST
PURPOSE:
Purpose of this test to evaluate finished product PROCEDURE:
1. Acquire sample
2. Visually check the sample
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3. Warm to sample to room temperature
4. Pour into sample cups
5. Swirl and evaluate odor
7.14 PH TESTING
PROCEDURE:
1. Acquire sample
2. Insert electrode in sample after rinsing with distilled water
3. Note the reading then again wash electrode with distilled water and place KCL
8 AQUAFINA SECTION
For the production of Aquafina, Raw water from the turbines is passed from various steps to
remove all the impurities resulting in the production of Treated Water. That Treated Water is
further processed for the production of Mineral Water “Aquafina”.
8.1 MINERALIZATION
Mineralization is a process in which mineral are added to water having zero TDS . After the
step of reverse osmosis minerals are added to the water having zero TDS.
Name of minerals are
1. KHCO3(for 2 units) =0.05kg
2. NaCl (for 2 units)=0.643kg
3. MgSO4 (for 2 units) =2.67kg
KHCO3 is added first due to less solubility than magnesium sulphate(MgSo4) is added
because it is more soluble than potassium bicarbonate and at the end NaCl is added due to
high Solubility.
28
Figure 6
8.2 SALTS
1. Potassium Bicarbonate (KHCO3)
2. Magnesium Sulphate (MgSO4)
3. Sodium Chloride(NaCl)
Treated
Water after
UV
Contact
Tank
Chiller
RO3
Caustic Dosing
Mineral Dosing Anti-scalant
Rinse
Tank
Batch
Tank
Filler
Ozonation CCP-1
PET Rinser
29
8.3 BATCHING PROCEDURE ( FOR 10 MINS )
1. After CIP, Take 350 Liter Deozonated water in one dosing tank from rinser tank.
2. 5 bags of potassium Bicarbonate pre Dissolved and add in mineral dosing tank.
3. 10 min mixing time
4. Add 5 bags of Magnissium Sulphate in mineral dosing tank
5. 10 min mixing time
6. Add 5 bags of Sodium Chloride in mineral dosing tank.
7. 10-15 mints final mixing
8.4 1 µM FILTER
It is used for extra protection prior to production. After the step of Mineralization water is
passed from 1 µm Filter to remove impurities of this filter size are greater than it.
8.5 PRODUCT TANK OR OZONATION
In product tank that water Is stored in which minerals are already added . water from
this tank leads to filler areas .In product tank 0.2 to 0.4 ppm ozone is added.
8.6 RINSING TANK
In rinsing tank water is stored having 0.2 to 0.4 ppm ozone and this water is directly
from 1 µm Filter .this water is not passed from the step of mineralization. Water from
rinsing tank moves toward filling area where it is used for rinsing of bottles.
8.7 RINSING
These bottles are rinsed with water having ozone. The process of bottle rinsing includes
certain steps at first step.
1. Bottle is captured in a stand.
2. Water is sprinkled by a nozzle which do washing.
8.8 FILLING OF WATER
30
After rinsing bottles are preceded from rinsing machine to filling machine which does
fixing of bottles and fill it a detector is present in these machines which give information to
the filling machine that bottle is now in front of it and ultimately machine start filling.
8.9 NITROGEN INJECTION
After filling of water single drop of nitrogen is added to the bottle to give it fluffy texture .
Machine used for condensing nitrogen gas into liquid form
8.10 CAPPING
After nitrogen injection caps are placed on the bottle. 8.11 NECK SLEEVE
Now bottle head portion is covered by sheet and detector is there which tells that cap
is not properly sealed. This bottle should be rejected on next step now this bottle moves on
conveyor belt a detector is there which help in the elimination of bottle not properly sealed.
After this, these bottles pass through shrinking chamber which have heaters on above side
and hot air is provided from lower side .this help in smoothing neck sleeve.
After passing from it sensor is there which detect the presence of bottle on conveyor
belt and give instruction to the printing machine to eject ink and print desired information
on the bottle. Then it is passed through packing machine which pack bottles in the bundle
of 9 or 12.
8.12 BLOWING OF PACKED PET BOTTLES
These packed bottles are blowed with blower to give cooling effect to packed pet
bottle crates. Because when it passed from packing machine.
8.13 STACKING
Crates of bottle are stacked and their shipment is done after 3 days because when
microbial and analytical testing give positive result their shipment is done.
9 AQUAFINA ANALYTICAL LAB
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9.1 INSTRUMENTS USED IN AQUA FINA ANALYTICAL LAB
9.2 PH METER
pH is negative logarithmic of concentration of H+ Ions PRINCIPLE
A pH meter measures essentially the electro-chemical potential between a known liquid
inside the glass electrode (membrane) and an unknown liquid outside. Because the thin
glass bulb allows mainly the agile and small hydrogen ion to interact with the glass. The
glass electrode measures the electro-chemical potential of hydrogen ions or the potential of
hydrogen.
PROCEDURE
1. Calibrate the pH meter with standard buffer solutions.
2. Rinse the pH Electrode with the demonized Water & clean it.
3. Immersed pH electrode into sample & note the pH.
9.3 CONDUCTIVITY METER
PRINCIPLE
Electrical conductivity is the ability of solution to transfer electric current. It is the
reciprocal of electrical resistivity (ohms).Therefore conductivity is used to measure the
concentration of dissolved solids which have been ionized. In a polar solution such as
water. The unit of measurement commonly used in one µohm or a seimen per centimeter.
When measuring more concentrated solutions, the units are expressed as milli-
seimens/cm.
PROCEDURE
1. Calibrate the conductivity meter with standard solution of NaCl (1000µS/cm)
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2. Rinse the pH Electrode with the Deionizer Water & clean it.
3. Immerse Conductivity Electrode into sample & note the conductivity.
9.4 TORQUE TESTER
CLOSURE
Removal & Incremental Torques PURPOSE
1. To determine closure application
2. And opening torque.
3. Improperly applied closures will not protect
4. The product integrity
5. Opening Torque=Force to release initial seal
6. Incremental Torque=Force to rotate 6o beyond original position.
PROCEDURE
1. Zero the display
2. Turn closure counter clock
3. Record removal torque
4. Turn closure clockwise (rotate 6 beyond original position.)
5. Record incremental torque
6. Check against specification
9.5 OZONE COMPARATOR
PURPOSE
This test is used to measure the amount of ozone present in the water.
PROCEDURE
1. The range of ozone in product is 0.2-0.4 ppm.
33
2. DPD 4 tablets are used.
3. Take 5 ml sample in test tube & add DPD 4 tablet.
4. Compare the color on comparator.
9.6 NET CONTENT
Principle:
Weigh the beverage in the bottle and note reading. Do empty the filled bottle and weigh it and note reading. Put the values in software and note the net contents. PURPOSE
To determine net content of finished product by weights measurement PROCEDURE
Acquire full sample
↓
Clean and dry bottle from outside
↓
Weigh bottle with mineral water
↓
Empty, rinse and dry the bottle
↓
Weigh the empty bottle
↓
Put values in software and determine the net content of mineral water
9.7 FILL HEIGHT
PURPOSE
It is used to measure the amount of water which is filled in the bottle.
PROCEDURE
34
1. Place the bottle on the smooth surface.
2. Place the vernier caliper’s side which is without counting on the surface of closure.
3. Note the reading on the scale till that surface, where the water is filled.
10 MICROBIOLOGY SECTION
Two types of CIP’s are done in RBL.
1. External CIP
2. Internal CIP
10.1 EXTERNAL CIP
It consists of
1. Foaming with oxoform/Detergent
2. Scrubbing with brush
3. Cleaning with Water
10.2 INTERNAL CIP
There are 3 types of Internal CIP
1. Hot water flush (3-step)
2. 3 step Divo Flow 185
3. 5 step caustic
10.3 SANITIZING AGENTS
1. Oxofom
2. Chlorine
3. Hot water
4. Caustic (1.5-2%)
5. Divo flow 185
35
10.4 3 TYPES OF INTERNAL CIP EXPLAINED
Internal CIP
3 step Divo flow
3 step Hot Water Flush
5 Step Caustic
1-Rinse with simple water.
1-Rinse with simple water.
1-Rinse with simple water.
2-Apply DF 185 at 1850 C.
2-Apply hot water (85 C) for 15-20 minutes.
2-Apply caustic at 85 C.
3-Wash it with cool water upto 250 C.
3-Cool down to 25 C.
3-Caustic clear with cool water to 25 C.
4-Apply hot water.
5-Cool down to 25 C with simple water.
Figure 7
11 SLICE TETRA PLANT
Slice mango is introduced in RBL in 2012. Slice orange and apple is introduced in 2014.
Slice juice (tetra pack) is a very sensitive plant line.
Filling process mechanism (Steps):
11.1 CREASING UNIT
Tetra pack shape is developed.
36
11.2 SA (SEAL TEST)
Seal with the help of pressure ruler. Pressure applied on the upper side.
11.3 FILER BATH
Apply H2O2 in the bath for killing the microbes. At 74C temp.
11.4 ASEPTIC CHAMBER(SQUEEZE RULER)
Use for removal of H2O2 particles.
11.5 AIR KNIFE:
Remove the remaining particles of H2O2 at 125C hot air.
11.6 PACKET SHAPE
Paper layer is coming from air knife shape of packet is developed and LS is applied.
11.7 FINAL FOLDER UNIT
Final formation of packet occurs.
11.8 THREE VALUES OF MACHINE
11.9 VALVE A:
Production is coming in this valve (by pass process).
11.10 VALVE B:
Sterilization (killing of microbe) at temp 270C.
11.11 VALVE C:
CIP (Clean in Process).
Steam Barrier: Flap sealing
11.12 MIXING PROCESS (STEPS):
1. Mixing
2. Homogenizer
3. Pasteurizer (CCP-2)
11.13 SLICE LAB TEST:
1. Weakly Test
2. Daily Test
3. Seal Test (Strip applicator. SA unit 60%)
4. Transversal Seal (Dolly and indicator)
37
5. Longitudinal Test (In chamber 40%)
LS test (Ink test)
TS test
6. Meter Test (Conductivity should be zero)
7. PH Test
8. Brick Test
9. T.A
11.14 PRODUCTION
In 1 min produce 125 packs in one hour 7500 packets.
12 RBL LAB Instruments
12.1 DEGASSER ASSEMBLY
Degas the sample.
12.2 SECURE SEAL TEST
Check the crown seal (pressure 150-165)
12.3 CARBO QC
Check the gas of bottle.
12.4 HOT AIR OVEN
Temp (50-300) provides heat to the sample.
12.5 REFRACTO METER
Sugar Test.
12.6 DENSITY METER
Check density, specific gravity, ethanol purity.
12.7 SPECTECTRO PHOTO METER
Sugar Analysis.
12.8 DE-AERATOR
Working base on ultra-sonic wave.
Remove Air Bubbles
12.9 HOT PLATE TITRATE
Use as stirrer.
12.10 TORQUE TEST
Force required opening the torque. Used for pet bottle test.
12.11 DEW TIME
38
To check the internal and external temp of the bottle.
12.12 T.A
Check titrate able acidity
13 CONCLUSION
This internship has made me expert in practical work. I have learnt about use of apparatus,
handling of advanced instruments, safety precautions and about the importance of practical work.
In instruments, I learnt about use of spectrophotometer, Refractrometer, Computer, Automatic
Ovens, Furnace, pH meter, Conductivity meter, and about very advanced apparatus which is
used in lab.
My internship for six weeks in QA/QC department can help me in my practical life. Based upon
this internship, I can do job in any industry of biochemical especially the maize products and in
any lab where synthesis of organic chemicals is done.
I myself have tested, analyzed and reported sample with shift-chemicals. So, I know a lot about
filling of log sheets and about how to finalize daily lab reports. This thing can help me to a
greater extent to be successful in interviews for job at industry.