BIOTECHNICAL AND MICROBIOLOGICAL ANALYSIS OF CARBONATED AND NON-

CARBONATED BEVERAGES AND WORKING OF WTP

IN

AS

SUMMER INTERNSHIP PROJECT REPORT 2010

SUBMITTED FOR PARTIAL FULFILLMENT

OF

B.Tech (BIOTECHNOLOGY)

DEGREE

OF

AMITY UNIVERSITY, UTTAR PRADESH

FROM

SUGANDHA VARSHNEY
A0504108443

TO

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 DECLARATION

I herby declare that the project titled “BIOTECHNICAL AND MICROBIOLOGICAL

ANALYSIS OF CARBONATED AND NON-CARBONATED BEVERAGES AND WORKING

OF WTP.” is an original piece of research work carried out by me under the

guidance and supervision.

The information has been collected from genuine and authentic sources. The work

has been submitted in partial fulfillment of the requirement for the award of

masters degree of business administration in biotechnology management and

submitted to Amity University, Noida.

Place: Delhi Signature:

Date: SUGANDHA

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 Acknowledgement

There are people who simply by being what they are try to influence you to do
things which you could never thought of. Their spontaneous and genuine help as
and when needed have helped me a lot, to gain profound knowledge and
experience in the analytical field.

My sincere thanks to HINDUSTAN COCA-COLA BEVERAGE PVT.

LIMITED which have given me the golden opportunity to do my project.

I feel pleasure to express my gratitude to Mr. Anuman Mathur to allow me to

undertake my project work in Microbiology Quality Assurance Laboratory,
Coca Cola for the relevant period.

I am grateful to Mr. Manoj Goel (Quality Manager) who encouraged me to

reach, much above my natural abilities through his inspiring guidance.

I am chiefly indebted to Mrs. V.S SHAKAMBARI (QA Executive) for her

constant encouragement, meticulous help, devoting her precious time and
invaluable guidance during the course of my project.

I would also like to thank Prof.A.K. Shrivastava (Director General, Amity

Institute of Biotechnology) for his proper guidance and help.

In a nutshell it is not a work of one but many others who by their sincere efforts
have contributed towards the completion of this project.

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 ABBERIVATION

°C : Degree Centigrade
2Na2CO3 : Sodium bi Carbonate
AHR : Anaerobic Hybrid Reactor
AT : Aeration Tank
ATCC : American Type Culture Collection
BGA : Brilliant Green Agar
BOD : Biochemical Oxygen Demand
BPA : Baired Parker Agar
BSA : Bismuth Sulphide Agar
CA : Cetrimide Agar
CaCl2 : Calcium Chloride
CaCO3 : Calcium Carbonate
CB : Cetrimide Broth
CIP : Clean In Place
CO2 : Carbon dioxide
COD : Chemical Oxygen Demand
DDS : Dodecyl Sulphate
DM : De-Mineralized
DMF : Dual Media Filter
DO : Dissolved Oxygen
DOP : Dioctylphthalate
EMB : Eosin Methylene Blue
FC : Final Clarifier
FeCl3 : Ferric Chloride
FRP : Fibre Reinforced Plastic
GC : Gas Chromatography
GMP : Good Manufacturing Process
H2CO3 : Carbonic Acid
H2O : Water
H2S : Hydrogen Sulphide
H2SO4 : Sulphuric Acid
HCl : Hydrochloric Acid

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K2HPO4 : Potassium Hydrogen Phosphate
KH2PO4 : Potassium dihydrogen Phosphate
KI : Potassium Iodide
KOH : Potassium Hydroxide
LAF : Laminar Air Flow
MgCl2 : Magnesium Chloride
MgCO3 : Magnesium Carbonate
MgSO4 : Magnesium Sulphate
MLSS : Mixed Liquor Suspended Solid
MnSO4 : Manganous Sulphate
MR-VP : Methyl Red – Voges Proskauer
MSA : Mannitol Salt Agar

Na2HPO4 : Sodium Hydrogen Phosphate

NaEDTA : Sodium Ethylene Diamine Tetra
Acetic Acid
NaN3 : Sodium Azide
NaOH : Sodium Hydroxide
NH3 : Ammonia
NH4Cl : Ammonium Chloride
NMT : Not More Than
N-Tank : Neutralization Tank
OF : Oxidation / Fermentation
PC : Primary Clarifier
PDA : Potato Dextrose Agar
PIA : Pseudomonas Isolation Agar
PVC : Polyvenyl Chloride
QA : Quality Assurance
QC : Quality Control
RI : Refractive Index
RO : Reverse Osmosis
S.BLANK : Seeded Blank
SCDA : Soyabean Casein Digest Agar
SCOT : Support Coated Open Tubular
SHMP : Sodium Hexa Meta Phosphate
SS : Suspended Solid
STP : Sodium Tri Phosphate
SVI : Sludge Volume Index
TDS : Total Dissolve Solid
TPC : Total Plate Count
TSI : Triple Sugar Iron Agar
TSP : Tri Sodium Phosphate
UL : Upper Limit
UV : Ultra Violet
VJA : Vogel Johnson Agar

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 WCOT : Wall Coated Open Tubular
INTRODUCTION

Soft drinks constitute one of the largest food industries in the world today. Tremendous

advances have taken place in the process technology in the soft drink industries in the past one

or two decades.

In India, in the organized sector alone, annual production of soft beverage is about 45 million

cases. The flavored component of most of the well-known brands of soft drinks is a well-

guarded secret.

The carbonated beverages are divided into two groups those with artificial flavor and those with

natural fruit juice.

The major ingredients of soft drinks are

• Flavor emulsion and emulsifiers

• Coloring agents

• Acids and preservatives

• Water

• Carbon dioxide

• Sugar and/or sugar substitute

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 Coca Cola : An Insight

ROOTS
While much of the world has changed since 1886, the pure and simple magic of one thing stays the
same - COKE. The name and the product represent simple moments of pleasure for consumers in
nearly 200 COUNTRIES around the globe, who reach for products of The Coca Cola Company
hundreds of millions of times every single day.
John Styth Pemberton first introduced The Refreshing Taste of Coke in Atlanta, Georgia. It was May
of 1886 when the pharmacist concocted a caramel-colored syrup in a three-legged brass kettle in his
backyard. He first ‘distributed’ the new product by carrying Coin a jug down the street to Jacobs
pharmacy. For five cents, consumers could enjoy a glass of Coat the soda fountain. Whether by
design or accident, carbonated water was teamed with the new syrup, producing a drink that was
proclaimed.

HISTORY
Coca Cola, the name and the product represent simple moments of pleasure for consumers in nearly 200

countries around the globe.

John Smith Pemberton first introduced the refreshing taste of Coca Cola in Atlanta, Georgia. It was

May of 1886 when the pharmacist concocted caramel coloured syrup in a three-legged brass kettle in his

backyard. He first distributed the new product by carrying Coca-Cola in a jug down the street to

Jacobs’s pharmacy. For five cents, consumers could enjoy a glass of Cola-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. Thus Coca Cola began as a fountain product.

In 1899 large scale bottling became possible when Asa Candler granted exclusive bottling rights to

Joseph B. Whitehead and Benjamin F. Thomas of Chattanooga, Tennessee. Today coca-cola products

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reach consumers and customers around the world through a vast distribution network made up of local

bottling companies. These bottlers are located around the world, and most are independent businesses.

Using syrups, concentrates and beverage bases produced by the Coca-Cola Company. The global

bottling system packages and markets products, then distributes them to more than 14 million retail

outlets worldwide.

The trademark “Coca-cola” was registered with the U.S. Patent and Trademark office in 1893, followed

by “Coke” in 1945.

In 1982, the Coca-Cola Company introduced diet coke to U.S consumers, marking the first extension of

the Company’s most precious trademark to another product. Later years saw the introduction of

additional products bearing the Coca-Cola name, which now encompasses a powerful line of cola

products. Today, the world’s favourite soft drink, Coca-Cola is one of the world’s best-known and most

admired trademarks, recognized by more than 90 percent of the world’s population.

DELICIOUS AND REFERESHING

Dr. Pemberton’s partner and bookkeeper, Frank M.Robinson, suggested the name and penner “Coke” in
the unique flowing script that is famous worldwide today. Mr. Robinson thought the “two would look
well in advertising”.
By 1891,
1891 Atlanta entrepreneur Asa G. Candler had acquired complete ownership of the Coca-Cola
Business. Within four years, his merchandising flair helped expand consumption of Coca-Cola to
every state and territory. In 1919, The Coca-Cola Company was sold to a group of investors for $25
million. Robert W. Woodruff became president of The Coca- Cola Company in 1923, and his more
than six decades of Leadership took the business to unrivaled heights of commercial success, making
Coca – Cola an institution the world over.

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FIRST BOTTLED

COKE began as a fountain product, but candy merchant Joseph A. Bedenharn of Mississippi was
looking for a way to serve this refreshing beverage at picnics. He began offering bottled Coke, using
syrup shipped from Atlanta, during an especially busy summer in 1894.
In 1899, large-scale bottling became possible when Asa Candler granted exclusive bottling rights to
Joseph B. Whitehead and Benjamin F. Thomas of Chattnooga. The contract marked the beginning of
The Company’s unique independent bottling system that remains the foundation of Company Soft
drink operations.
As the Company had many imitators, which consumers would be unable to identify until they took a
sip. The answer was to create a distinct bottle for Coke. As a result, the genuine Coke bottle with the
contour shape now known around the world was developed in 1915 by the Root Glass Company

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 VISION OF COKE

AWARDS

Hindustan Coca-Cola Beverages Private Limited, Dasna unit, bags the “Golden
Peacock Environment Management Award 2004”

The Dasna unit near Delhi in Ghaziabad has been awarded the prestigious “Golden
Peacock Environment Management Award – 2004 (GPEMA- 2004)” for excellent
environment practices and effective control of environmental impact

RAW MATERIAL TESTING

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 1. TESTS FOR CARBON DIOXIDE

a) ODOR (SNOW TEST)

Procedure:

1 Collect liquid CO2 (snow) in plastic bag (approx 550cc)

2 To a flask add about 200 ml treated water then add about 250cc of snow and cover

immediately

3 Swirl the liquid in flask and sniff odor in headspace. No odor should be there.

Typical off odors

- Fruity

- Rotten egg, sewer, silage, sulfury

- Acetaldehyde

- Hydrogen sulfide

2. TESTS FOR SUGAR

a) TASTE

1 Make 50 obrix solution

2 Take 10 ml of this solution and make upto 100 ml

3 Check the taste of this sample

b) ODOR

1 Half fill a wide mouth screw capped bottle with dry sugar

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 2 Heat to 500C

3 Smell and note the nature of any off odor.

c) ODOR AFTER ACIDIFICATION

1 Smell the 50 brix solution at room temperature and note any off-odor

2 Add 0.2ml 75% w/v phosphoric acid to 50 ml of sugar solution in a 100 ml glass beaker and

mix

3 Cover the beaker with a watch glass and heat to 50 C in a water bath or incubator.

4 Smell the solution every 10 min for 30 min and note the nature of any off odor.

d) TURBIDITY

1 Prepare 492g of 50 brix solution by dissolving 246 g of sugar in 246 it distilled water.

2 Examine the 50 brix solution in a glass beaker.

3 Turbidity meter reading must be <10 NTU

4 If turbidity is present, fitter the sample through whatman 54 and examine filtrate for

turbidity. Use if no turbidity is present.

e) MICROBIOLOGICAL TESTING

1 Weigh 10g sugar in a sterile 250ml flask and add sterile 100ml water upto the mark. Cover

with a foil and agitate to dissolve sugar.

2 Pour the solution into filter funnel.

3 Cover the funnel, apply vacuum

4 Wash the flask twice with 250ml sterile water.

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 5 Transfer the membrane to a sterile Petri dish (M-TGE medium for total count and M-green

yeast and mold medium or Schaufus- Pottinger medium for yeast and mold count) and

incubate at 350 C or 280C

6 For total count, count the colonies at 24 hrs and at 72 hours. For yeast and mold count, count

colonies at 48 hrs and at 24 hrs interval thereafter until 5 days have lapsed.

f) COLOR (ICUMSA)

1 Weigh 50 gm of sugar sample in a 250 ml conical flask; add 50 gm of Tri Ethanol Amine

solution (weigh 7.460 gm TEA in a beaker and make up to 500 ml.). Dissolve it by

swirling.

2 Filter the solution through 0.45 micron filter.

3 Set the spectrophotometer at 420 nm.

4 Rinse the cell with sugar solution and then fill with sugar solution.

5 Keep TEA solution as standard blank.

ICUMSA = ABSORBANCE X 1000

Cell Length (in cm) x conc.(g/cm3)

3. TEST FOR CONCENTRATE

The following points must be taken care of with regard to concentrates:

1) Sanitary condition: Storage in clean, dry, closed area free from insect infection.

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2) Temperature: Storage temperature is between 4 to 10*C /ambient for dry base. No refrigeration

should be done until required to do so.

3) First in First out: The oldest stock in hand should be used first.

4) Stacking and Sorting:They should be kept on wooden platforms, above the floor right side up and

yet not very high above the ground.

5) Inspection: The containers must be scrutinized for seal damage leaks, date of production and other

damages.

6) Sealing of containers: Partly used containers contents must be transferred to glass or stainless steel

containers and then used as early as possible.

PACKAGING MATERIAL TEST

The finished products are packaged in cartons and are dispatched for the market. The

tests ensure the suitability of the packet for the market, as a packet of insufficient strength would

spoil all the efforts of carefully manufactured product.

# RGB (RETURNABLE GLASS BOTTLES)

Procedure for sampling of RGBs

Select 50 samples from each incoming consignment of 22000 bottles

• Draw samples from min. 5 different crates / bulk packs with bottles of different mould nos. for

equitable sample representation

• Maintain linkage between samples drawn and the consignment. This shall enable resampling,

resorting quarantine of the sampled lot if required.

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• Inspect the Glass bottles as per the quality plan.

# CROWNS

Specification for crowns

• By matching decoration of samples with standard crown.

• By Go No Go.

GO

Go NOGO

NoGo

# WRAP AROUND LABELS

Procedure for sampling of Wrap around labels

• Select 50 wrap around labels, randomly from each incoming lot of 35000 – 150000 labels

• Maintain linkage between samples drawn and the consignment. This shall enable resampling,

resorting quarantine of the sampled lot, if required.

• Inspect the Wrap around label as per the quality plan taking samples one from each bundle of

200 labels.

Blowing PET and Bottle washer

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# PET SECTION

Temperature set point (penetration oven) : 116.0˚C

Percent output (oven) : 80.9 %

Feeding temperature : 125.0˚C

Oven temperature : 218.8˚C

Exterior temperature : 35.8˚C

Bottle pressure : 59.3 bar

Perform temperature : 114.9˚C

FLOW DIAGRAM

Hopper for loading of performs loading rail

Oven

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 Penetration oven Distribution oven

Level panel

Material distribution

By Air By heating

Middle arm

Perform transfer arm

Stretching (7bar)

Deep blow (7-30) Mould process of blowing start (die)

Main blow (41bar)

Chiller (19.3˚C)

Filling section Chain conveyor

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Types of PREFORMS used

• 25gm for 500ml Bottle

• 25gm or 28gm for 600ml Bottle

• 28gm for 1 ltr. Bottle

• 48gm for 1.5 ltr. Bottle

• 54gm for 2 ltr. Bottle

Bottle washing

Empty bottles handling

Removal of foreign material

Bottle washing in washer Pre wash, Soak1,2,3, and Final Rinse

Inspection of returnable bottles

Ready for filling

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 CSD Bev

B o ttlin g
U n c a s in g o f b o ttle s re c e ive d fro m
m a rk e t

P re-in s p e c tio n o f e m p ty b o ttle s

B o ttle W a s h in g
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INTRODUCTION TO QUALITY ASSURANCE

• It is the total arrangement made with the object of ensuring that beverage products are of the
quality required for their intended use.

• The system of quality assurance appropriate to the manufacture of food products should ensure
that:

a) Beverages are designed and developed in a way that accounts of the requirements of
GMP and associates codes such as those of good laboratory practice GLP and good clinical
practice (GCP).

b) Production and control operations are clearly specified in a written form and GMP
requirements are adopted.

c) Arrangements are made for the manufacture, supply, and use of the correct starting and
packaging material.

d) All necessary control on starting materials, intermediated products, and bulk products and
other in process controls, calibrations and validations are carried out.

e) The finish product is correctly processed and checked, according to the defined
procedures.

f) Beverages are not sold or supplied before the authorized person have certified that each
production batch has been produced and controlled in according with the requirements of the

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 label claim and any other regulations relevant to the production, control and release of
pharmaceutical products.
g) Satisfactory arrangements exist to ensure, as for as possible, that the pharmaceutical products are
stored by the manufacturer, distributed and subsequently handled so that quality is maintained
through out their shelf life.

h) There is a procedure for self – inspection and/or quality audit that regularly appraises the
effectiveness and applicability of the QA system.

• To achieve the quality objective reliably there must be a comprehensively designed and
correctly implemented system of QA incorporating GMP and QC.

MICROBIOLOGY LAB
To distinguish the food of acceptable quality from food of unacceptable
quality required the application of what are known as microbiological criteria.
Three different types of microbiological criteria have been identified.
1) A microbiological standard is a criteria specified in a law or regulation.
It is a legal requirement that foods must meet and is enforceable by the
appropriate regulatory agency.
2) A microbiological specification is a criteria applied in commerce. It is a
contractual condition of acceptance that is applied by a purchaser
attempting to define the microbiological quality of a product or ingredient,
failure of the supplier to meet the specification will result in the rejection of
the batch or a lower price.

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 3) A microbiological guideline is used to monitor the microbiological
acceptability of a product or process. It differs from the standard or
specification in that it is more often advisory than mandatory.
The microbiological laboratory of QA is well equipped and maintained.
All the microbiological work is carried out in it.

COMMONLY USED INSTRUMENTS IN MICROBIOLOGY LAB

• AUTOCLAVE

An Autoclave

An autoclave is a pressurized device designed to heat aqueous solutions above their boiling point to
achieve sterilization. It was invented by Charles Chamberland in 1879.[1] It is used for moist heat
sterilization, which is carried out at 121°C for 30 minutes at 15 psi. Media is sterilized by autoclave
Under ordinary circumstances (at standard pressure), liquid water cannot be heated above 100 °C in
an open vessel. Further heating results in boiling, but does not raise the temperature of the liquid water.
However, when water is heated in a sealed vessel such as an autoclave, it is possible to heat liquid water
to a much higher temperature. As the container is heated the pressure rises due to the constant volume
of the container (see the ideal gas law). The boiling point of the water is raised because the amount of
energy needed to form steam against the higher pressure is increased. This works well on solid objects;

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when autoclaving hollow objects, however, (hypodermic needles, tools, etc.), it is important to ensure
that all of the trapped air inside the hollow compartments is vacuumed out.
Autoclaves are widely used in microbiology, medicine, veterinary science, dentistry and metallurgy.
The large carbon-fiber composite parts for the Boeing 787, such as wing and fuselage parts, are cured
in large autoclaves

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 • INCUBATOR

An Incubator

An incubator comprises a transparent chamber and the equipment that regulates its temperature,
humidity, and ventilation. For years, the principle uses for the controlled environment provided by
incubators included hatching poultry eggs and caring for premature or sick infants, but a new and
important application has recently emerged, namely, the cultivation and manipulation of
microorganisms for medical treatment and research. It is used for providing favorable temperature
conditions for the growth of culture organisms. Generally the temperature of incubator is operated at
37°C for the growth of microorganisms

Laboratory incubators were first utilized during the twentieth century, when doctors realized that they
could be could be used to identify pathogens in patients' bodily fluids and thus diagnose their disorders
more accurately. After a sample has been obtained, it is transferred to a Petri dish, flask, or some other
sterile container and placed in a rack inside the incubator. To promote pathogenic growth, the air inside
the chamber is humidified and heated to body temperature (98.6 degrees Fahrenheit or 37 degrees
Celsius). In addition, these incubators provide the amount of atmospheric carbon dioxide or nitrogen
necessary for the cell's growth. As this carefully conditioned air circulates around it, the microorganism
multiplies, enabling easier and more certain identification.

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 • CENTRIFUGE
A centrifuge is a piece of equipment, generally driven by a motor, that puts an object in rotation around
a fixed axis, applying force perpendicular to the axis. The centrifuge works using the sedimentation
principle, where the centripetal acceleration is used to separate substances of greater and lesser density.
There are many different kinds of centrifuges, including those for very specialised purposes
It is used to separate the suspended matters as pallets/button/residue from the liquid as supernatant.

• MICROSCOPE

A Microscope

A microscope is an instrument for viewing objects that are too small to be seen by the naked or unaided
eye. The science of investigating small objects using such an instrument is called microscopy. The term
microscopic means minute or very small, not visible with the eye unless aided by a microscope. The
microscopes used in schools and homes trace their history back almost 400 years

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 • pH METER

A pH meter is an electronic instrument used to measure the pH (acidity or basicity) of a liquid A typical
pH meter consists of a special measuring probe (a glass electrode) connected to an electronic meter that
measures and displays the pH reading.It is used to obtain pH value of different sample calibration is
done carried out with standard buffer solution of pH 4.0, 7.0, 10.0

A simple pH meter with its probe immersed in a mildly alkaline solution. The two knobs are
used to calibrate the instrument

• LAMINAR AIR FLOW UNIT

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LAF unit is used for providing sterilized airflow by means of High Efficiency Particulate Air (HEPA)
filters
• HOT AIR OVEN

A Hot Air Oven

It is used for dry heat sterilization. Glassware’s, Petri plates and pipettes are packed in stainless
steel containers and kept at 180°C for 2 hrs.

• BOD INCUBATOR

A BOD Incubator
It is used for fungal growth at 22°C.

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• CYCLOMIXER

It is used to mix the suspended particles.

• STOMACHER LAB BLENDER

It is used for dissolving sample without the destruction of the organism for which the cost is to be
carried out. Sample + dilution is placed in the recommended bags provided the total volume should
be with in recommended capacity of the machine (80 – 400 ml).

• WEIGHING BALANCE

It is a precious weighing instrument for small load. It is used primarily in professional and
technical application. It is calibrated against standard weights.

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• MICROBIOLOGICAL TESTING:
Different types of media used in microbiology lab to test microbiological count in various samples.

Media used for water testing:

Water being the essential component of beverage industry is tested against microbes using various
media.

1. Chloramphenicol yeast glucose agar:

Standard formula:
Yeast extract: 5.00 gms/ltr
Dextrose: 20.00 gms/ltr
Chloramphenicol: 0.10 gms/ltr
Agar: 14.90 gm/ltr

PH (at 25 c) 6.6 + 0.2

Directions: Suspend 40.0 Gms of salt in 1000ml distilled water. Heat to boiling to dissolve the
medium completely. Sterilize by autoclaving at 15lbs pressure at 121 c temperature for 15 mins.
Use : To check yeast and mold in water .

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2. Violet Red Bile Agar:
Standard Formula:
Peptic digest of animal tissues: 7.00 gms/ltr
Yeast extract: 3.00 gms/ltr
Lactose: 10.00 gms/ltr
Bile salts mixture: 1.50 gms/ltr
Nacl: 5.00 gms/ltr
Neutral Red: 0.03 gms/ltr
Agar: 15:00 gms/ltr
PH (at 25 c) 7.4 + 0.2
Directions: Suspend 41.53 gms of salt in 1000 ml distilled water. Heat to boiling to dissolve the
medium completely. Cool to 45 c and immediately our into sterile petri plates containing the innoculum.
If desired, medium can be sterilized by autoclaving at 15lbs pressure at 121 c temperature for 15 mins.
Use: For selective Isolation, detection and enumeration of Coli – aerogens bacteria in water, milk and
other dairy food products.

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3. EMB Agar:

Standard formula:
Peptic digest of animal tissues: 10.00 gms/ltr
Dipotassium phosphate: 2.00 gms/ltr
Lactose: 5.00 gms/ltr
Sucrose: 5.00 gms/ltr
Eosin –Y: 0.40 gm/ltr
Methylene Blue: 0.005 gms/ltr
Agar: 13.50 gms/ltr

PH (at 25c) 7.2+0.2

Directions: Suspend 36 gms in 1000 ml distilled water. Heat to boiling to dissolve the medium
completely. Dispense and Sterilse by autoclaving at 15lbs pressure at 121 c temperature for 15 mins.

Use: Used for differential isolation of Gram-ve enteric bacilli from clinical and non- clinical specimen.

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4. CC2:

Standard Formula:
Yeast extract: 9 gms/ltr
Creoles: 50 gms/ltr
Bio Peptone: 10 gms/ltr
Magnesium Sulphate: 2.10 gms/ltr
Potassium sulphate: 2.00 gms/ltr
Diastase: 0.05 gms/ltr
Thiamine: 0.026 gms/ltr
Bromo Cresol Green Agar: 15.00 gms/ltr

PH (at 25 c) 4.6+0.2
Directions: Suspend 8.82 gms in 1000 ml distilled water. Mix thoroughly. Heat to boiling to dissolve
the medium completely. Dispense and Sterilse by autoclaving at 12-15lbs pressure at (118- 121 c)
temperature for 15 mins.

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Use: For counting yeast and moulds in samples by membrane filter method.

Media used for checking and controlling microbial count in MAAZA.

5. Orange Serum Agar:

Standard Formula:
Casein enzymatic Hydrolysate: 10 gms/ltr
Yeast Extract: 3 gms/ltr
Dextrose: 4 gms/ltr
Dipotassium Phosphate: 2.50 gms/ltr
Orange Serum Agar (solid from 200 ml): 17 gms/ltr
PH (at 25 c) 5.5+0.2
Directions: Suspend 45-5 gms in 1000ml Distilled water. Heat to boiling to dissolve the medium
completely. Dispense and Sterilse by autoclaving at 12-15lbs pressure at( 118- 121 c) temperature for 15
mins. Avoid overheating . Mix well and pour into Sterile Petri plates.

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Use: For Cultivation and enumeration of micro- organisms associated with spoilage of citrus products.
Cultivation of Lacto bacilli and other aciduric organism and pathogenic fungi.

INVERSION:

INVERTED BRIX: This is the brix which is found after breaking of sucrose in two parts and molecular
weight increases due to water molecule addition in the presence of acid.
C12H22O11 + H2O C6H12O6 + C6H12O6
(SUCROSE) (GLUCOSE) (FRUCTOSE)
(342) (180) (180)
(A) (B) {360}

(A) Sucrose is 95% of (B) because of that

Inverted Brix * 95 = actual brix
100
Procedure:

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1) Expel the CO2 from the sample properly.
2) Take 50 ml of decarbonated Sample in a cleaned and dry bottle after rinsing the bottle twice with the
decarbonated beverage.
3) Add 0.3ml of the HCl stock solution (made for inverted brix checking) in the 50ml of the sample.
4) Cap the bottle properly and keep in water bath to reflux it at 900C for 90 mins.
5) Now cool down the sample to room temperature.
6) Check the brix and note down it.

Inverted Brix should be = (Std. Brix of the flavour/0.95) +- 0.15

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 WATER TREATMENT

INTRODUCTION

The bottling plant receives its water supply from 3 bore wells .This water is first treated and then used

for beverage preparation.

NEED TO TREAT WATER

Water is treated to remove:

 Colloidal and suspended particles.

 Undesirable odor, taste and color.

 Reduction in alkalinity to desired level.

 Micro organisms.

COMMON IMPURITIES IN WATER

 Suspended solids: Includes all matter suspended in water that is large enough to be retained on

a filter with a given porosity.

 Turbidity: Indicates level of colloidal matter of organic or inorganic origin.

 Ph: Concentration of hydrogen ions in water.

 Alkalinity: Indicates the quantifiable quantities of carbonates, bi carbonates and hydroxides in

water.

 Total hardness: Indicates the quantifiable quantities of calcium and magnesium.

 Total dissolved solvents: Indicates total content of dissolved solids in water.

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COAGULATION STREAM

Raw Water Tank

Free chlorine (2-3ppm)

Coagulation Tank

Lime, bleaching pd., FeSO4

Clear Water tank

Pressurized Sand Filters

(PSF)

Dechlorination

Activated Carbon Filters

- 37 -
 (ACF)

Lead ACF

Lag ACF

5 micron filter

UV chamber

3 micron filter

1 micron filter

Treated water

- 38 -
 USES OF TREATED WATER

 Syrup making, beverage preparation and CIP.

 Filler for cleaning and flushing.

 Water coolers.

 Back washing of PSF and ACF of treated water lines.

SOFTENING STREAM

Raw water

P.S.F.

A.C.F.

Softener (24% brine)

Soft water

- 39 -
 USES OF CHLORINATED SOFT WATER

 Bottle washer.

 Crate washer.

 PET rinser.

USES OF NON CHLORINATED SOFT WATER

 Boiler.

 Chiller.

 PET blower.

 Cooling system.

- 40 -
 VARIOUS WATER TREATMENTS

Functions of different water Treatment Process

1) Chlorination

Scope

 Destruction of micro organisms.

 Oxidation of heavy metal ions and organic impurities.

2) Coagulation and Flocculation

Scope

 Reduction of alkalinity.

 Removal of dirt clay and other suspended matter.

 Removes microbial matter

 Heavy metals and compounds causing off taste.

Chemicals Used

 Lime: Reduces alkalinity and temporary hardness.

 Bleaching Powder: Removes color, turbidity, kills microbes and acts as a coagulant aid.

 Ferrous sulphate: Used as a coagulant for quicker settlement of suspended particles.

 Soda Ash : Reduces permanent hardness and is used when total hardness in water is

higher than total alkalinity.

- 41 -
3) Pressure Sand Filter

Scope

 Removes colloidal material

 Removes suspended micro particles

Media Used – 6 layers of sand ranging from coarse gravel to fine sand.

Optimum Flow Rate

 Pressure should no exceed 4.8 m2/hr/sq meter of surface area in case of PSF.

 Pressure should not exceed 8.5 m3/hr/sq meter of surface area for Gravity Sand Filter

Back Wash Frequency – Done when turbidity 0.4 NTU (Normally once in 24 hrs.)

Sanitation – Done by 50 ppm chlorine solution.

4) Activated Carbon Filter

Scope

 Removes trace level of organic compounds

 Removes color, taste and odour causing compounds.

Media Used – Activated Carbon (by adsorption)

Optimum Flow Rate – Should not exceed 9.6 m3/hr/sq meter of carbon bed

Back Wash and Sanitation Frequency

 Turbidity 0.5 NTU

 Depends on the chlorine carry over

 Sanitation done by steam at 1.5 kg for around 4 hrs at a temp of 85 C.

 Normal frequency once in 8 days.

- 42 -
5) Softener

Scope – To reduce the hardness of water.

Medium Used – Sodium resins

Resin Quantity – 1500 ltr. (Ex: Indion 225)

Working Principle – Na+ will be exchanged with the hardness causing elements.

Regeneration

 Depends on the hardness of output water5 (generally every 4 days)

 Done by 24% brine (NaCl) solution.

Sanitation – Done by Formaldehyde solution with a contact time of 24 hours.

Sanitation Frequency – Depends on micro count

6) Polishing Filtration

Scope

 Removes granular activated carbon particles and send particles

 Flakes of scale or rust

Media Used – Micron filters (5, 3, 1 & 0.2)

7) Ultra Violet Purification System

Scope – Destroys or inactivates the DNA thus preventing micro organisms from reproducing.

Media – Ultra violet lamp radiation of 2537 Angstrom units.

8) Reverse osmosis

Scope – To remove dissolved salts and minerals and micro organisms

- 43 -
Media – Semi Permeable membrane.

Principle – Forcing the solution of higher concentration through a semi permeable membrane

leaving behind the dissolved ions and suspended solids.

Reverse osmosis (RO) is most versatile technology available to bottling and canning plants

today

 It reduces alkalinity and total dissolved solids by more than 90 %

 Reduces inorganic such as Na, Cl, SO4

 Reduces large organic molecules and organisms at efficiency more than 99%

The usual molecular weight range is below 300 Dalton

Operating pressure range is from 200 – 450 psi.

Filtration is done below 0.001 micron

Advantages:

 Highly effective against a wide spectrum of contaminants.

 Easy to operate.

 Cost effective when designed properly

 Minimum space requirement

 Can handle changes in water supply and level of impurities.

Disadvantages:

 RO membrane should be protected against fooling by Fe and silicates.

 Polyamide membranes must be protected against effects of chlorine.

 Cellulose acetate membranes are biodegradable.

- 44 -
 Efficiency of unit affected by the temperature of raw water.

 Higher the organic content of incoming water, less effective the unit.

 The effluent waste water from system pose disposal problems

KINLEY WATER MANUFACTURE

Water from bore well

Coagulation

PSF

Storage tank

Dechlorination ACF

Two tier ACF

- 45 -
 UV chamber

Reverse osmosis

Reverse osmosis membrane filtration process

Storage tank

Micron filter

Proportioner Concentrate

Blending

Ozonation

Filling and capping

- 46 -
 Warmer and blower

Labeling

Date coding

Packaging

Palletizing

WATER TREATMENT PLANT TESTING

1. Chloride test:-

Take 50ml sample in a conical flask

Add 2 drops of P. indicator

Add 0.02N H2SO4

(Until pink color disappears).

Add 5 drops of potassium chromate or 0.5ml

- 47 -
 (Removes turbidity)

Titrate it with N/50 AgNO3

(End point –brown color)

NaCl (mg/ltr.) = (R-0.2ml) 23.376

Where,

R – Reading

2. Sulphate test:-

100ml sample

2 drops of P. indicator

Add 1N HNO3 until the color disappear

Boiling to expel CO2

Make up to 200ml by distill water

Cool it & allow to settle

From above soln. take 50ml

- 48 -
 Add 1ml NH3 buffer

Add black tincti-cation

Titrate with N/50 EDTA

End point – Blue color

3. Total hardness:-

• Standard for total hardness (< 100 ppm)

Procedure:-

Take 100ml of water sample in a conical flask

Add 3 – 4 drops of ammonia buffer

Add a total hardness tablet

- 49 -
 Mix thoroughly

(Pink color appears)

Titrate it with N/50 EDTA soln.

Development of blue color

(Indicates the presence of total hardness)

Result: - Observation is less than 100ppm.

4. Alkalinity:-

• Standard for alkalinity(< 85 ppm)

Procedure:-

Take 100ml of water sample in a conical flask

Add 2 – 3 drops of Ph indicator

- 50 -
 Add 4 – 5 drops of Methyl orange or Methyl purple

Development of orange yellow color

Titrate it with N/50 H2SO4

Darkning of orange yellow color

(Indicates the presence of Alkalinity)

Result: - Observation is < 85ppm

Note: - Burette reading should be multiplied by 10 to get alkalinity

5. Chlorine test:-

• Standard for chlorine (b/w 3 – 5ppm)

Procedure:-

Take 10ml of sample in micro quant bottle

- 51 -
 Kept it in colorimeter

Add one Cl2 – 1A tablet powder

Observe color

Development of dark pink color

(Indicates the presence of chlorine)

# To observe mid readings do testing as follows:

Take 50ml of chlorinated water and

50ml non chlorinated water in a measuring cylinder.

Mix it thoroughly and fill it into two cubettes

Add powder of one DPD tablet to one cubette

- 52 -
 DPD gives pink color

(Pink color indicates the presence of chlorine)

6. Calcium hardness:-

Procedure:-

Take 100ml of sample water

Add 3 – 4 drops of NaOH

Add one CaH tablet powder

Gives light pink color

Titrate it with EDTA soln.

- 53 -
 Pink color slightly darkens with purple touch

(Indicates the presence of CaH)

7. Magnesium hardness:-

Procedure:-

Same as Calcium hardness

MgH = TH – CaH

Where,

MgH – Magnesium hardness

TH - Total hardness

CaH – Calcium hardness

8. Turbidity:-

• Collect the sample in a clean dry glass beaker, transfer the sample to the sample

cell quickly

• Rinse the sample cell with the water to be tested

• Cap the cell and dry the outside surface of the cell with a tissue paper.

• Pour the sample into the sample cell

- 54 -
 • Examine the water sample in the cell before placing it in the instrument. If bubbles

have formed on the inside wall of the cell; gently tapping on the cell wall or mildly

agitate the cell to release the bubbles

• Gently invert sample once to agitate any particulate that may have settled

• Place the cell in the turbidity meter with the direction mark on the cell forward

• Lower the light cover and the turbidity will be displayed

• Record the turbidity

9. P – test (alkalinity):-

Phenolphthalein indicator gives pink color if alkalinity is there.

10. TDS (total dissolved solids):-

Measured by TDS meter

SYRUP MAKING PROCESS

First raw syrup is made. This raw syrup is mixed with concentrate of the required beverage

flavor. The formulated ready syrup Brix is prepared for beverage manufacture.

SYRUP PREPARATION

Clear raw syrup is prepared by two different methods -

- 55 -
 Batch System

 Continuous System

BATCH SYSTEM

Treated Water

Sugar dissolving tank

Heating (85 Deg cent)

Addition of sugar

Contact time 30 min

Filter

Precoating

Filtration in Plate and frame filter press

- 56 -
 Pressure difference-In-2.5kg/cm2 Out-2.0kg/cm2 cooling

Plate heat exchanger Refrigerant-Glycol &cold Water (by water-up to 35 Deg cent

followed by glycol 22-40 Deg cent)

Simple raw syrup

Mixing with concentrate

Ready syrup

CONTINUOUS SYSTEM (Capacity: 5000 ltr/hr)

Treated Water

Heating (PHE) to 85 Deg cent

Carbon Sugar

- 57 -
 Contisolv

Mixing and dissolving

Holding (85 Deg cent-30 min)

Filtration

Buffer tank

Bag Filter

Cooling (PHE) [Pasteurization]

Syrup Tank

- 58 -
 Concentrate addition

Ready syrup

BEVERAGE MANUFACTURING PROCESS

Manufacturing beverage and filling in RG or PET bottles is the major part of the plant.

The ready syrup is blended with treated in required proportion by two types of proportioners

namely MOJONNIER and PARAMIX. The HCCBPL holds 4 MOJOs and 1 PARAMIX

machine.

THE MOJJONIER AND THE PARAMIX

Basic functions

• Deaeration.

• Proportioning.

• Carbonation.

• Cooling.

• Maintaining counter pressure.

Major equipments

• Deaerator.

• Water and syrup reservoirs.

• Carbotrol.

• PHE

• CC / buffer tank.

- 59 -
 • 3 pumps

De aerator tank

• PM valve.

• NRV

SCFM meter

• Air outflow vent valve

• Perforated baffle plates

• Level floats

After De aeration

• Some CO2 will also escape along with air.

• DO level after De aeration should be less than 2ppm.

• SCFM – 10 (approx) – If DO exceeds 2ppm then SCFM is increased.

Proportioning principle

• Mojonnier:

Works on the principle of flow through an orifice syrup and water are made to pass through

orifice of different diameters, under same pressure. The orifice diameters is set as per the

mixing ratio.

• Paramix:

- 60 -
Works on flow control valves. As per the mixing ratio settings the flow control valves open

to allow the desire quantity of syrup / water to flow

Mojonnier – a semi automatic m/c

• Manual operations:

- Micrometer setting for proportioning.

- Carbon-dioxide flow control.

- Beverage flow control to PHE.

• Automatic functions:

- Level control of various tanks (through PH valves).

- Sequencing, synchronization and on-off control of various inter connected

devices.

- Control of various valves during CIP.

Main factors affecting carbonation / maintaining saturation

• Temperature: lower the temperature higher the carbonation

• Time: higher the contact time b/w carbon-dioxide and product, higher is the carbonation.

• Pressure: higher the CO2 pressure, higher the carbonation.

• Surface area: more the contacts / surface area of water, more is the carbonation.

• Nature of bvg. : Higher the solubility of the beverage for CO2, higher the carbonation.

• Dissolved oxygen: lower the initial DO in the beverage, the higher is the carbonation.

- 61 -
 Process flow diagram

Treated Water CO2 Ready syrup

(From WTP) (From bullet) (From syrup room)

Micron filter

De aerator

Feed Pump
Feed Pump

Water Syrup
Reservoir Reservoir

BLENDING

- 62 -
 TO FILLER

AN OVERVIEW TO MANUFACTURING PROCESS

Depalletizing (Not in case of PET)

Uncasing (Not in case of PET)

Sorting / Removal of Foreign Matter (Not in case of PET)

Pre Inspection (Not in case of PET)

Bottle Washer (Blowing in case of PET)

Post Inspection (Not in case of PET)

- 63 -
 Proportioner

Filling & Closing

Date Coding

Final Inspection

Casing

Palletizing

1) DEPALATIZING: Separation of bottle cases from palate.

It is carried out manually, and cases are supplied to conveyer, for uncasing.

2) UNCASING: Removing of bottles from case. It is carried out by using uncaser machine.

- 64 -
3) PRE INSPECTION: Bottles are manually inspected for foreign material inside, mixed

bottles, dirty bottles etc.

4) BOTTLE WASHING:

Bottle washing is completed in following stages:

1) Pre-rinse:- Here empty bottles are rinsed by water used in first rinse.

2) First soak: - Bottles are soaked in surface active reagent solution like caustic and BW 61.Here

temperature is 60 deg cent and pressure is 2-3 bars.

3) Second soak: - First soak is followed by second soak, here temperature is maintained at 74

deg cent and pressure is at 2-3 bars.

4) Third soak: - Here again temperature is maintained as that of first soak.

This section wise soaking is carried to avoid thermal shocks to bottles .the temperature

difference between two soaks should not be more than 15 deg cent.

5) Rinse: - Here rinsing is carried out in four stages as first, second, third and final. For rinsing,

treated soft water is used. The flow of water is from final soak to first soak. Water from first

soak is used in pre rinse

5) PROPORTIONER:

Machine used for mixing of syrup, carbon dioxide and water in proper proportion is called as

Proportioner

It contains following major parts:

1) Deairation

2) Proportioning

3) Carbonating unit

- 65 -
 4) Cooling unit

1) De aeration: Its primary purpose is to remove dissolved oxygen from the incoming water

supply. De aeration can be achieved by

 Vacuum system

 CO2 stripping

 Combination of both systems

De aeration is essential for high speed bottling lines and ambient filling. Other benefits of De

aeration are:

 Necessary to meet standards for canned product

 Less air equals more accurate proportioning on CO2 control

 Less foaming

 Greater product stability

 Lesser product oxidation

 Less chances of contamination

 Important in achieving maximum filling speeds especially in ambient filling process

2) Proportionating: Proportioning equipment accurately blends finished syrup with water at the

correct ratios or proportions

Different methods used are

 Fixed head over office method

 Batch blending

- 66 -
  Mass metered blending

 Continuous flow blending

3) Carbonation: Carbonation utilizes physical characteristics such as temperature, pressure,

surface area and contact time to facilitate the absorption of carbonation into beverage.

The primary function of the carbonating unit is to add CO2 to the product so that the standards

for that final product are met.

Carbonation can be achieved by

 CO2 injection

 CO2 education

Factors affecting carbonation include:

 Product type

 Product temperature

 CO2pressure

 Time and contact surface area

 Air content

4) Cooling: The relationship between temperature and CO2 pressure in the carbonating process

is critical. Cooling should be consistent during production so that CO2 pressure established will

give a constantly stable carbonation level in the product.

This can be done by:

 Plate coolers

- 67 -
  Shell and tube chillers

During mixing it is critical that the system be capable of producing a consistent product within

standards, be readily cleaned for product changeover and tend itself to the sanitation programme

used by the plant.

6) FILLING:

The operational principle is based on 4 functions

1) Positioning

2) Pressurizing

3) Filing

4) End of filling

5) Closing & decompression

1) Positioning: The bottles are transferred to the bottle lift plates from where a vertical thrust

provided by compressed air raises the bottles towards the filing valves.

2) Pressurizing: A pneumatic valve opener causes gas from the filler bowl to flow into bottle

placing it under pressure.

3) Filling: When the pressure in bottles reaches the same pressure as filler bowl the liquid valve

opens and liquid flows down into bottles and the gas in the bottle is pushed back to the filer

bowl.

4) End of filling: The filling stops when the liquid in the bottle reaches the month of the vent

tube, blocking the gas exit and the return of the gas to the filler bowl.

- 68 -
5) Closing and decompression: Thereafter, the liquid and pressure valve are closed by

mechanical control. The gas left in the neck of the bottle is shifted out and the bottle is

decompressed. The bottles are descended back to their lower positions from where they move

for crowning.

Each filler manufacturer rates their filter at specific operating speeds of the size and type of

package to be filled in addition to product carbonation and filling temperature.

7) CROWNING:

Crowning applies the closure to the filled bottle.

The basic types of closures and closing equipment are

 Crowns: For glass bottles.

 Plastic closures : For PET bottles

The function of the crowner is to mechanically apply and seal crowns to bottles. This uses a

crimping technique that applies pressure to the top and sides of the crown. This pressure causes

the crown to adapt to the neck of the bottle

The capper applies a pre-threaded plastic closure on the bottle, centers and pre tightens the

closure onto the bottle. The final stage seals to a pre-set dynamic torque. When the pre set

torque is reached, the clutch steps to prevent further tightening.

8) PACKAGE LABELLING:

Labellers are used to apply labels to returnable stock bottles and PET containers. Labels can be

used for special sales or promotions. Sleeve labels have the advantage of more consistent

operation with no glue application

- 69 -
Labels can be made of:

 Plastic laminate

 Paper

 Combination of material

9) DATE CODING:

Date coding matter should include following information.

 Date of production.

 Time of production.

 Batch number

 Line identification.

The coder is installed on the production line and identifies the filled beverage package as to

establish

 Production date

 Regulatory requirements

 Mandatory information

This information’s would allow plant to check back if there were any problems with that

production and to effectively manage the age of inventory in trade.

Various types of codes include:

 Mappings on paper labels

 Ink jets

 Video jets

- 70 -
  Lasers

In ink-jet coding, the container is dried by air or steam. Pressurized steam of ink passes through

nozzle and is broken into droplets by negative electric charge. Droplets are deflected and

directed to containers forming an alphanumeric code.

Test for date code:-

 Rub test: - Slight rubbing on date code print in one direction for
ten times. If it affects the print on sample it is failed and if not

then it passes the test.

Rub test is carried out with respect to different storage conditions.

1) Ageing: - In this test samples is allowed in open atmosphere for 24 hr and then test is carried.

2) Refrigeration:-In this test sample is allowed to refrigeration condition for 24 hr and then test

is carried.

3) Ice Immersion:-In this test sample is kept in ice water for 24hr and then test is carried.

10) FINAL INSPECTION:

The beverage filled bottles are again passed through a manual inspection station where the

beverage is scrutinised for appearance, clarity, presence of any particulate matter, and half

filled bottles. Rejected bottles are removed before packaging into cases

- 71 -
11) CASING:

Mechanically by using caser machine casing is carried out.

12) WAREHOUSING:

The filled bottles are arranged in cases and through a belt conveyor system are taken to the

shipping or warehouse area where they are stored till they are marketed.

SANITATION

The most important sanitation programme in the beverage plant deals with cleaning and

sanitizing of the surfaces that come in contact with syrup beverage, or ingredients in their

preparation.

Proper sanitation performed at the recommended frequency will minimize and most

likely completely eliminate the potential for bacteria, yeast and mold reproduction and growth.

The CIP (Clean in place) programme is done every 48 hrs of a run or after a flavor change. In

case of Kinley water it is done every 24 hrs of run. The CIP is done with the help of computer

fed programme of SIEMENS Company. There are two types of CIPs done.

4 step CIP

 Pre rinse of treated water 10 min

 Hot water rinse 20 min (85 deg C)

- 72 -
  Final rinse with treated water 10 min

6 step CIP

 Pre rinse with treated water 10min

 Hot caustic rinse (1.5% - 2.5% of caustic with a temp. of 73 ˚C) 15 min

 Rinse with treated water 10 min

 Hot water rinse (85 ˚C) 20 min

 Final rinse with treated water 10 min

WASTE WATER MANAGEMENT

The disposal of waste water from the bottling plants pose specific problems with respect to

pollution control specifications.

Effluent from bottling plants consists of organic matter, decomposition or draining of which in

open atmosphere may cause serious problems with regard to production of obnoxious odour,

harm to vegetation and other living species (aquatic life).

This kind of water may not be fit for recreational and other purposes; therefore it is essential that

water may be stabilized biologically before discharging into stream or any other body of water.

- 73 -
 EFFLUENT TREATMENT PLANT

• Plant Capacity--2000m3/day

• Aerobic System--Activated Sludge Process

Physical Treatment

Chemical Treatment

Biological Treatment

Raw effluent (pH-14)

- 74 -
 Bar screen first

Collection sump (40min)

Breaker chamber

Simple water

Bar screen second

Straw &fine waste

Oil and grease trap

Oil skimmed out

Equalization tank-I &II

(1990 m3 capacity)

Ph is maintained at 8.5 by using HCl (conc.)

- 75 -
 Homogenous mixing

Neutralization tank

(Ph is maintained at 8.5)

Aeration tank-I

(4 aerators having 55 hp motor each)

BOD is reduced by 70%

Clarifier –I

(370 m3 capacity)

To settle the sludge

Sludge is removed and sends to

Sludge drying beds

Aeration tank – II

(1 aerator having 30 hp motor)

BOD is reduced by 30%

- 76 -
 Clarifier - II

Treated water

Summary

Soft Drink Mixing Carbonation and Bottling Sequence

Treated water Syrup tank

Deaerator Syrup pump

Metering (synchrometer)

- 77 -
This device then meters the syrup and water in fixed proportion to the carbonator.

CO2 Cooler carbonator

The carbonated beverage then goes to the bottling or canning line, when it is admitted to sanitize

containers under a carbon dioxide pressurized atmosphere to prevent loss of carbon dioxide and

beverage boiling.

Cans or bottle filler

Bottle sealing (closure/crowns)

Storage

Soft drinks are generally sweetened, flavored, acidified, artificially carbonated and some

times chemically preserved. The history of establishment of soft drink industry in India lies for

more than the last four decades. The multinational soft drink company coca cola entered the

Indian market few years after independence while Pepsi entered the Indian in 1989. Coca cola

has captured a good market in different flavors namely Coca cola, ThumsUp, Fanta, Fanta

splash, Limca, Sprite, Sprite ice, Sprite zero, Diet coke, Kinley water, Kinley soda.

- 78 -
In the manufacturing of these soft drinks first of all treatment of water is done in WTP i.e. hard

water changes to soft water then syrup is prepared by mixing the sugar in desired ratio. After

this CO2 is added to beverage in carbo- cooler. After this filling and capping is done at filler

point after this labeling is done and then bottles are kept on crates with the help of case packer

machine. Then storage is done at room temperature. A systematic quality control is essential in

every plant. In plant, quality control testing must start with the raw materials. Sampling and

testing of raw materials will provide on basis for accepting or rejecting the raw materials and

give useful information to obtain a finished product of the desired quality and self life.

Conclusion

The legal view point demands that the quality of products confirming to National and

International standard Industries, therefore, have a special responsibility to ensure that their

products are safe as well as successful in the market place.

• Improved quality of product

• Achievement of greater consumer satisfaction

• Increased consumption and sales

• Promotion of National and International trades

• Greater confidence in the mind of consumer.

Quality control leads to:-

- 79 -
• Raw material control.

• Inspection of finished beverages.

• Sensory evaluation.

• Packaging.

• Labeling and storage.

REFERENCES

- 80 -