Inplant Training Report-Coke2009

Inplant Training at Coca-Cola
INPLANT TRAINING REPORT

(01 JAN 2009 to 31 MARCH 2009)
A.P - Pirangut, Taluka-Mulshi

Dist. - Pune- 411004
PATKI PRASHANT JANARDAN

(05T47B)
In the partial fulfillment of the

B.TECH (Food Science & Technology)
COLLEGE OF FOOD TECHNOLOGY,
PARBHANI-431402 (MAHARASHTRA)
MARATHWADA AGRICULTURAL UNIVERSITY.PARBHANI
College of Food Technology, Parbhani.

Certificate
To whom so ever it may concern
This is to certify that PATKI PRASHANT JANARDAN
(05T47B) from College of Food Technology, Parbhani
Has successfully completed the Inplant Training in “Hindustan Coca-Cola
Beverages Private Limited, Pune Unit”
From 1st JAN to 31h MARCH 2009, in the partial fulfillment of the
B.Tech (Food Sciences & Technology) curriculum as prescribed by College of
Food Technology, Marathwada Agricultural University, Parbhani.
Bankim Naik
Shashank Joshi
(Factory Manager)
QA Manager
HCCBL
HCCBL
Sanjay Uppadye
Baba Shetty
Team Leader (QA)
Team leader (QA)

ACKNOWLEDGEMENT
I have undergone Three Months In plant Training at HINDUSTAN COCO-

COCO-
COLA BEVARAGES PVT. LTD. PIRANGUT., PUNE,
PUNE to fulfill the requirements of
curriculum of my course B.Tech (Food Science & Technology).
I have immense pleasure in expressing my deep sense of gratitude,
indebtness and sincere thanks to Dr. P. R. Shivpuje ( Dean & Director of
Instruction)
Instruction and Prof. D. M. Shere (Associate Professor & I/C inplant training),
College of Food Technology, Parbhani faring me an opportunity to undergo
inplant training at, Hindustan Coca-
Coca-Cola Beverages , Pvt. Ltd., Pirangut,
Pirangut Pune.
I express my sincere thanks to Bankim Naik(Factory Manager), Shashank
Joshi (QA Manager), Phanindar Jamula(Production & Maintenance manager),
Dhiraj Batoyhita (Area HR Manager),Mr.
Manager) Mr. Sanjay Upadhye(Team
Upadhye(Team Leader QA),
,Mr. Baba Shetty (Team Leader QA), for giving me chance to undergo in plant
training at Hindustan Coca-
Coca-Cola Beverages, Pvt. Ltd., Pirangut, Pune.
Pune
And also I express my sincere thanks to all lab personnel’s Mr. Manish
Bhosle, Mr.shashikant Sawant, Mr. Mandlik Appasaheb, Mr.Deepak Diwe,
Mr.Yogesh Bhoi, Mr. Virendra Patil, Mr.Mahesh Wani, Mr.Sudhir Panase, and
Mrs. Vaishali, Ms Pranjal and all QA Executives for their valuable inspiration,
guidance & unforgettable co-operation during the training period.
I take this opportunity to thanks my family members, friends Mahesh,
Mahesh,
Vrushali, Darshan, Priyanka, Akhil, Ravi and all others helping me directly or
indirectly in plant training and stay at Pune only.
- Patki Prashant

Contents…..
1. Introduction
2. Certificate
3. Acknowledgment
4. About COKE
5. Products of COKE
6. Plant layout
7. Organizational setup
8. Instruments in lab
9. Details of products manufacture
10. RMPM & Microbiology
11. Process manufacture
• Water treatment Plant
• Syrup making
• Beverage manufacturing in PET/CAN
• Polyethylene Terephtalate-Advantages & limitations
• Carbonation-Basic Consideration
• Carbonation Measurement
• Feeling Principle
• Beverage manufacture in RGB
• Bottle washer
• Online quality checks
12. Cleaning in place
13. Boiler section
14. Refrigeration Section
15. Effluent Treatment Plant (ETP)

About Coke….
The manufacturing unit of Hindustan Coca-Cola Beverages (P) Ltd. Pune is
located at scenic and peaceful environs of village Pirangut, Taluka. Mulshi and
Dist. Pune, just 18-20 Km from Pune city. The plant commenced operation in
January 1996. Spread over 25 acres, the Pirangut plant is the only plant with
canning facility for Coca-Cola & production of Diet coke in India. The main
business of the company is to produce and distribute the products of the Coca-
Cola Company. The brands being currently produced are Coca-Cola, Thums Up,
Limca, Fanta Apple, Fanta Orangey Blast, Sprite, Diet Coke and Kinley Soda.
• First plant commissioned by TCCC in India- 1996

• PET LINE: - First Commissioned in Jan. 1996. (To Dec.1999)
• PET LINE:- Second Commissioned in March 2003
• CAN LINE:- Commissioned in Jan. 1996
• RGB LINE:- Commissioned in May 2000
The production facility of Pune plant is capable of producing
RGB: - 36000 cases/day,
PET: - 12000 cases/day,
CAN: - 66000 cases/day.
The sales territory of HCCBPL, location is at south Maharashtra state
extending from Raigrah to Nanded and Pune to Sindhudurg. The
manufacturing site is located on an area of around 1, 15,342 m2, and has two
number of filling lines for manufacture of RGB, PET and CAN. This
Quality System relates to the full range of company activities as determined
by the standards describe in TCCMS

Origin of Coke…
John stitch pemberton started coca-cola drinks in Atlanta’s Jacobs
Pharmacy in 1986. John was borne in 1831 in tiny village Knoxville, Georgia, in
1831; Pemberson had trained in college of pharmacy from pharmacy school in
Philadelphia. He first practiced his trade in Oglethorpe before moving to Columbus
after relocating in Atlanta in 1869, pemberton begin to experiment extensively
with extract of coca leaf and cola nut, initially marketing a moderately successful
health drink called “French Wine Coca”, John Pemberton with his four partners
coined and trademark the term “coca-cola”
Pembertons new and small company grew rapidly after it acquired by
Asa griggs Candler between 1889 –91 outlined the company basic strategy-
manufacture and distribution of coca-cola syrup to be mixed with carbonated water
at the soda fountain.
In 1886, sales of Coca-Cola averaged 9 drinks per day. That first, Dr
Pemberton sold 25 gallons of syrup, shipped in bright red wooden kegs. Red has
been distinctive colors associated with the No.1 soft drinks brands ever since. For
his efforts, Dr Robinson Grossed $ 50 and spent $73.96 on advertising. By 1891,
Atlanta entrepreneur Asa G. Candler had acquire complete ownership of Coca-
Cola business. IN 1892 G Candler to core the business and incorporated the coca-
cola company in Atlanta- Georgia with an aggressive marketing cam. Within 4
years, his merchandising flair help expend consumption for $ 25 million. Robert
W. Woodruff became president of Coca-Cola Company 1923 and his more than 6
decades of leader ship took the business to unrivalled heights of commercials
success, making Coca-Cola an Institution the world over. This year E. Neville
Isdell has been appointed as the 12th global CEO and Chairman of the Coca-Cola
Company.

Arrival of COKE in India….

While the Coca-Cola Company is global company and has completed 119
years of consumer service with some of the world’s most widely recognized
brands. The Coca-Cola business in India, as in each country where they operate, is
a local business. Their beverages are produced locally, employing Indian citizens,
their product range and marketing reflects Indian tastes and lifestyles.
After a 16-years absence, Coca-Cola the world’s favorite soft
drinks returned to Indian market in 1993 with its launch in Agra. The company’s
presence in India was cemented in November that year in a deal that gave Coca-
Cola ownership of the nation’s top soft-drinks brands and bottling network. Coca-
Cola India has made significant investments to build and continually improve its
business in India, including new production facilities, wastewater treatment plants,
and distribution systems and marketing equipment.
Coca-Cola business systems employ over 15,000 local people in
India. Virtually all the goods and services required to produce and market Coca-
Cola locally are made in India.
The Coca-Cola systems in India comprise 27 wholly owned
company-owned operations and another 17 franchise-owned bottling operations.
A network of 29 contract-packers also manufactures a range of products for the
company.

PRODUCTS OF COKE…
COCA-COLA
The world’s favorite drinks and most valuable brand. Cola

has a truly remarkable heritage. From a humble beginning in 1886, it is now the
flagship brand of the largest manufacturer, marketer and distributor of non-
alcoholic, beverages in the world. It is positioned as a mind refresher. Coke is
available in 200ml&300ml in glass. 600ml, 1.25, 1.5, 2lit and lit in PET and 330
ml in CANS. The product can use for a period of two &half to six months from
date of packing. Thumps Up is a leading carbonated soft drink and most trusted
brand in India. Originally introduced in 1977 and later on was acquired by the
Coca-Cola Company in 1993. Thumps-Up is known for its strong, fizzy taste and
uniquely masculine attitude. This brand clearly seeks to separate the men from the
boys .Available in same size and pack as above.
FANTA
Fanta entered the Indian market in the year 1993. Over the years
Fanta has occupied a strong market place and is identified as “The Fun

Catalyst”Fanta stands for its vibrant color, tempting taste and tingling bubbles that
not just uplifts feeling but also helps free spirit thus encouraging one to indulge in
the moment. Fanta is available around the country in 200ml, 300ml, 600ml, 1.25
Lit, 1.5Lit, 2.25Lit and 330ml Cans
DIET COKE
Diet Coke was born in 1982 and quickly became the No.1 sugar-
free in diet –conscious America. As Diet Coke in the U.S, Canada, Australia and
Great Britain, And Coca-Cola lights in other countries, it’s now the No. 3 soft
drink in the world. It’s the drink for people who want no calories, but plenty of
taste.
KINLEY WATER
Water, a thirst quencher that refreshes a life giving Force that

washes all the toxins away. Water, the most basic need of life, the very sustenance
of life, a celebration of life itself. The importance of water can never be
understood. Kinley water understands the importance and value of this life giving
force. Kinley water thus promises water that is as pure as it is meant to be. Water
you can trust to be truly safe and pure. Kinley water comes with the assurance of
safety from the Coca-Cola Company. That is why company introduced Kinley with
reverse-osmosis along with the latest technology to ensure the purity of the
product. That’s why we go through rigorous testing procedures at each and every

location where Kinley is produced. Because we believe that right to pure, safe
drinking water is fundamental. A universal need that cannot be left to chance.
Available in 1lit and 2lit PET.
LIMCA-
The drink that can cast a tangy refreshing spell on anyone, anywhere.
Born in 1971, Limca has been the original thirst choice, of millions of consumers
for over 3 decades. The brand has been displaying healthy volume growth year on
year and Limca continues to be the leading flavor soft drinks in the country with a
market share of 12% The success formula of Limca lies in its sharp fizz and lemoni
bite combined with the single minded positioning of the brand as the ultimate
refresher has continuously strengthened the brand franchise. Available in same size
and pack as above expect CAN.
SPRITE
Worldwide Sprite is ranked as No.4 soft drinks and is sold in

more than 190 countries. In India, Sprite was launched in year 1999 and today it
has grown to be one of the fastest growing soft drinks, leading the Clear lime
Category. Today Sprite is perceived as a youth icon. Its clear crisp refreshing taste
encourages the today’s youth to trust their instincts, influence them to be true to
who they are and to obey their thirst. Sprite advertising has always been

memorable with very high recall value, especially amongst the youth. Sprite is
available around the country in 200ml, 300ml, 600ml, 1.25lit, 1.5lit, 2lit, 2.25lit,
and 330ml Cans
MAAZA
Maaza was launched in 1976. It was a drink that offered the same
real taste of fruit juice. In 1993, Maaza was acquired by Coca-cola India. Maaza
currently dominates the fruit drink category. Over the years, brand Maaza has
become synonymous with Mango. It is available in SKUs of 200ml RGB,
250mlRGB, 125ml Tetrapack, 200ml Tetrapack.
FANTA APPLIE
This is new product now ready to jump in the market having enchanting
taste of fresh apple. This thirst quenching drink has already started in some part
of India.

FLAVOURS MANUFACTURED AT PUNE UNIT
IN RGB (200ML & 300ML)

THUMS UP
COCA COLA
FANTA APPLE
FANTA ORANGY BLAST
LIMCA
SPRITE
KINLEY SODA
IN PET (600ML, 1.25LTR, 1.5LTR, 2 LTR)

THUMS UP
COCA COLA
FANTA APPLE
FANTA ORANGY BLAST
LIMCA
SPRITE
KINLEY SODA (600,1.5 LTR)
IN CAN (330ML)
DIETCOKE
THUMS UP
COCA COLA
FANTA APPLE
SPRITE
CANISTERS
POSTMIX (Each 18 liter)
FANTA
SPRITE
COCA-COLA
THUMS UP

Plant Layout
ETP
Admin block
/ Utility area
Prodn Hall /
WTP /
Warehouse
Main Gate
Entry

Organizational Setup
Area General Manager
Finance Manager Sales Manager RTM Manager Factory Manager Area Capability Manager HR Manager
Quality assurance Techno-Commercial Production/Maintenance

Manager Manager Manager
Team Leader
QA Executives Microbiologist Production Maintenance
PET/CAN line Team Leader Team Leader
RGB Line
Production Maintenance
Process Executives Executives
Effluent
Treatment Operation Operation
Plant technologist technologist

Departments in Coke…
All the plant operations can be broadly classified into four main areas
namely
1. Warehouse
2. Production
3. Process/Quality
4. Utilities
Apart from these, the general functions such as HR, Finance, Sales, etc. exist
in coordination with them.
QUALITY DEPARMENT –
Quality is nothing but the “Degree of Excellence”. Quality Department is
responsible for all parameters related to quality from overall process staring from
raw materials to finished goods.
Quality Department ensures the operations of
1. Inspection of Raw Materials.
2. Water Treatment Plant.
3. Syrup Preparation
4. Online Quality of beverage manufacturing
5. Effluent Treatment Plant.
6. GMP & Housekeeping.

Instrumentation
Quality Assurance Lab Microbiology Lab Packaging Lab Effluent Treatment Plant Lab
Digital pH meter Laminar air flow Bursting strength tester Digital pH meter with
Density meter Digital colony counter Magnamike for thickness combined electrode
Gas volume tester Autoclave measurement Cod apparatus
Turbidity meter Incubator Enamel rating tester BOD incubator
Total dissolved solids meter Sterile filtration assembly Digital vernier caliper Vacuum pump
Spectrophotometer meter Digital weighing balance Mechanical can cutter Hot air oven
Vacuum filtration assembly Video seam monitor Stirrer set up
Flocculator for jar test Secure seal tester Muffle furnace
Water bath top load tester
Jar Test Apparatus Hot wire bottle cutter
Base clearance gauge
Hamilton beach blender
Go-no go gauge for crown crimping
Conductivity meter
Digital weighing balance
Distillation assembly
Torque tester
Gas volume & air content tester in cans
Lovibond comparator
Lovibond iron tester

DETAIL OF PRODUCT MANUFACTURE…
GENERAL INFORMATION
Soft drinks means sweetened carbonated beverage. In soft drink, there are
three main ingredients, which are as follows,
1. Water
2. Carbon dioxide;
3. Sugar
ABOUT SOFT DRINKS:-

Soft drinks have been part of the American lifestyle for more than 100 years;
many of today’s soft drinks are the same as the first ones enjoyed in the
1800’s.Soft drink production begins with creation of flavored syrup using a
closely-guarded company recipe; the syrup is mixed with purified water and then
carbonated by adding carbon dioxide gas under pressure. This carbonation creates
the “Tingly Fizz” that gives soft drinks a refreshing taste.
SOFT DRINK INGREDIENTS:-

Like other foods, the ingredients that are used in soft drinks are approved and
closely regulated by the U.S. Food & Drug Administration (FDA) .All of the
ingredients used in soft drinks are found in a variety of the foods.
WATER:-
Soft drink production starts with a pure source of water.
Regular soft drinks contain 90% water while diet coke soft drinks contain 99%
water. Drinking water often contains trace amount of various elements that

affects its taste. Ii is noticed that tap water tastes different in various regions of
the country. Bottlers use sophisticated filtering & other treatment equipments to
remove any residual impurities and to standardize the water used to make soft
drinks. That is why our soft drink tastes the same in all over the world.
CARBON DIOXIDE:-
A colorless & odorless gas, carbon dioxide is essential characterizing ingredient
in all carbonated beverages. It is given off when we breathe and is used by plants
to produce oxygen.
When dissolved in water carbon dioxide imparts a unique taste , for that reason
natural sources of carbonated or effervescent, mineral water were once highly
priced ,These rare mineral waters also believed to have beneficial medicinal
properties.
It was the innovative step of adding flavors to these popular soda water that
gave birth to the soft drink beverages we enjoyed today. In the early days of soft,
drink manufacturing, carbon dioxide was made from sodium salts .This is why
carbonated beverages were called as Sodas or Soda Water.
Today bottlers buy pure carbon dioxide as a compressed gas in high-pressure
cylinders, carbon dioxide gas is absorbed in to the flavored soft drinks in a
carbonator just before the container or bottle is sealed. While under pressure and
chilled the soft drink may absorb up to four times the beverage volume of carbon
dioxide.
SWEETENERS:-
For soft drinks, normally cane sugar is used, but now due to classification of
soft drinks there are types of sugars, which are use in soft drink manufacturing.

1. FOR NON-DIET SOFT DRINKS:-

Most regular (non-diet) soft drinks are sweetened with either SUCROSE or
HIGH FRUCTOSE CORN SYRUP (HFCS).A mixture of these sweeteners may
also be used. Sucrose, the familiar sweetener comes from sugar cane or sugar
beets. HFCS is a newer and more convenient liquid sweetener, similar to
sucrose but made from corn. It is now use in many prepared foods. With either,
the amount of sugar or sweetener in a soft drink ranges from 7 to 14 %.
Both sucrose and High Fructose Corn Syrup are easily digested
carbohydrates, and carbohydrates are an important part of the diet. They
provide calories, which are the source of energy for the body.
Sometimes thoughts to be more fattening than other foods, sugar actually
contains the same no. of calories by weight as protein (4 calories/gram) , and
less than half the calories of fat(9 calories/gram). Sugar also contains far fewer
calories than alcohol (7 calories/gram).
DIET SOFT DRINKS:-

The popular class of beverages known as Diet Soft Drinks, which are made by
the intensely sweet substances we refer to as “DIET” or “LOW CALORIE”
sweeteners. Aspartame, Saccharin, Sucrose, and Acesulfame-k are approved
sweeteners for use in soft drinks.
ASPARTAME:-
The use of intense sweeteners has increased significantly over the past 20 years
owing to the appearance, and acceptance, of new types in the market.
Saccharin, the first intense sweetener to be used on a commercial scale, has a
difficult taste profile that can seldom be masked with any success in application.
During its long history (initially being employed as a substitute for sugar in the

case of diabetic patients around 1890), consumers have had to accept its often
bitter/metallic aftertaste. In 1983 aspartame and acesulfame K were approved for
use under the European Sweeteners Directive/Amendment 96/83/EC and
immediately found favor in the soft drinks industry (aspartame in particular) as a
replacement for saccharin. Although aspartame provides a clean, lasting sweetness,
it has the disadvantage of undergoing hydrolysis and loss of potency during
storage. Below pH 3 and above pH 5, hydrolysis will occur relatively swiftly;
hence conditions in the range pH 4.2–4.3 are required, where maximum stability is
achieved. Aspartame and saccharin have been successfully used in combination,
and also with acesulfame K, where a more sugar-like taste may be achieved.
Because of the phenylalanine content in aspartame, a warning statement is required
on the label of products containing the sweetener. In the UK the words ‘contains a
source of phenylalanine’ must appear on the label to enable those who suffer from
phenylketonuria (an inherited disorder in which the enzyme that converts
phenylalanine into another amino acid, tyrosine, is defective) to factor the
consumption of aspartame into their daily intake calculations. After many years of
scientific testing aspartame was first approved for use in some foods in1981 and
for soft drinks in 1983.It has been reviewed and approved, not only by the U.S.
Food and Drug Administration (FDA), but also by the Governments of more than
60 countries, and the World Health Organization (WHO). Aspartame is a
“Nutritive” sweetener meaning it is easily digested and provides calories. However
it’s sweetening power is greater than sucrose.
FLAVOR:-
One of the major & important ingredients in soft drink is flavoring. Most soft
drink bottlers mix many individual flavors to create distinctive taste.

Natural flavors in soft drinks come from spices, natural extracts & oils, fruit
flavored soft drinks such as orange & lemon –lime often contains natural extract.
There are also some artificial or manmade flavoring used in soft drinks,
nature does not produce enough of some flavors to satisfy worlds demand , Also
some natural flavors are limited geographically & seasonally.
COLORS:-
Many people do not realize how important color is to taste
perception, color affects our physiologically impression of food. If we don’t
believe it, try eating food in the dark, the colors used in food and beverages
come from both natural and synthetic sources.

RAW MATERIAL SAMPLING PLAN & TESTING PROCEDURES

(RMPM)
Following are the raw materials, which are used in carbonated soft drink
industry: -
SUGAR –
Sugar is one of the major ingredient uses in soft drink industry, for
production of soft drinks special grade sugar is used from selected sugar factories.
SUGAR ANALYSIS -
Coca Cola Company has its own standards for quality of sugar,
-Frequency: - Each delivery
The sugar sample is drawn from at least 10 bags from different sites/layers from
the truck or from the stores.
1. The sample is mixed thoroughly in a container to produce a composite sample.
2. Consignment data collected with the sugar sample includes:
- Supplier’s name and location
- Date and time of delivery
- Quantity delivered
- Transportation vehicle number
3. The sugar is then tested as per the frequency for the following parameters:
• Appearance
• Taste
• Odor
• ICUMSA Color
• Odor after acidification
• Turbidity
• Ash by Conductivity

• Microbiological Analysis
4. If the sugar is from a new supplier, all parameters are tested according to the
Granulated Sucrose Specification for India (The sugar is then analyzed for each
of the above parameters. Sugar lots not meeting the specification are rejected
CARBON DIOXIDE –
Carbon dioxide was one of the first gases to be described as a substance distinct
From air. The Flemish chemist Jan Baptist van Helmont in the early seventeenth
Century noted that when he burned charcoal in a closed vessel, the mass of the
Resulting ash was much less than that of the original charcoal. He interpreted that
The rest of the charcoal must have been transmuted into an invisible substance he
Termed a ‘gas silvestre’, which we now know as carbon dioxide. Carbon dioxide
was studied more thoroughly by a Scottish professor of medicine, Joseph Black.
He found that limestone (calcium carbonate) could be heated or treated with acids
to yield a gas that he called ‘fixed air’. He observed that this fixed air was denser
than air and did not support either flame or animal life. He also found that this gas
would, when bubbled through an aqueous solution of lime (calcium hydroxide),
precipitate calcium carbonate. He used this phenomenon to demonstrate that
carbon dioxide is produced by animal respiration and microbial fermentation.
Carbon dioxide is a colorless, non-toxic, inert gas that is virtually tasteless
And is readily available at a reasonable cost. It is soluble in liquids, the degree of
Solubility increasing as the liquid temperature decreases and can exist as a gas,
Liquid or a solid. When dissolved in water it forms carbonic acid. It is carbonic
acid. That produces the acidic and biting taste found in carbonated waters and soft
drinks. Above a certain level of carbonation carbon dioxide has a preserving
property, Having an effective antimicrobial effect against moulds and yeasts. It

achieves this With moulds by depriving the moulds of oxygen required for growth
whilst with Yeasts it tends to stop the production of more carbon dioxide as a by-
product of the Fermentation of sucrose to ethanol. Carbon dioxide gas is heavier
than air, having a density of 1.98 kg/m3 at 298 K, some 1.5 times that of air. It has
a molecular weight of 44.01 and does not burn, though it will support the
combustion of magnesium. As it is fully oxidized, it is not very reactive. It is a
fairly stable compound that only decomposes at very high temperatures into carbon
and oxygen. It can cause death by suffocation if inhaled in large amounts. The gas
is easily liquefied by compression and cooling. When liquid carbon dioxide is
quickly decompressed it rapidly expands and some of it evaporates, removing
sufficient heat so that the rest of it cools into solid carbon dioxide. Carbon dioxide
is a waste product in organisms that obtain energy from breaking down sugars or
fats with oxygen as part of their metabolism. This process is known as cellular
respiration. This includes all animals, plants, many fungi and some bacteria. Plants
utilize carbon dioxide during photosynthesis thereby constructing carbohydrates. In
higher animals carbon dioxide is primarily held in solution in the blood which
transports it from the body’s tissues to the lungs to be exhaled. It makes up some
0.038% by volume of the earth’s atmosphere. In various parts of the world it is
formed underground and issues from fissures within the earth. This happens
notably in Italy, Java and Yellowstone National Park in the USA. Carbon dioxide
is a known contributor to the greenhouse effect, the balance in the atmosphere
increasing each year thus disrupting the natural carbon dioxide cycle. The initial
carbon dioxide in the earth’s atmosphere was produced by volcanic activity. This
was essential for a warm and stable climate conducive to life. Current volcanic
releases are some 1% of that released by human activities. The earth’s oceans
contain a large amount of carbon dioxide in the form of bicarbonate and carbonate
ions and much more than that found in the atmosphere. The carbon dioxide is in

the form of bicarbonate and carbonate ions, the bicarbonate being produced in
reactions between rock, water and carbon dioxide. An example is the dissolution of
calcium carbonate:
CaCO3 + CO2 + H2O _ Ca2+ + 2HCO-3
Such reactions tend to buffer atmospheric changes. Reactions between carbon
dioxide and non-carbonate rocks also add bicarbonate to the oceans. These
reactions can later be reversed to form carbonate rocks thereby releasing half of the
bicarbonate as carbon dioxide. This has produced large quantities of carbonate
rocks over the last few million years. So much now exists that if all these carbonate
rocks were converted back to carbon dioxide, the resulting level of carbon dioxide
would weigh 40 times as much as the rest of the atmosphere. Eventually most of
the carbon dioxide added to the atmosphere will be absorbed by the sea and
become bicarbonate ions, the process taking about one hundred years to achieve.
Carbon dioxide can exist as a solid, a liquid or a gas. The effect of temperature
And pressure on the state of carbon dioxide can be seen from the phase diagram of
carbon dioxide. At the triple point carbon dioxide can exist simultaneously
In the three states as a solid, a liquid or a gas by just a small perturbation. All
Phases are in a state of equilibrium at the triple point. This exists at 5.11 bar and
-56.4.C. above 31.C it is impossible to liquefy the gas by increased pressure. This
Is termed the critical point. At normal temperatures and pressures carbon dioxide
Is a colorless gas. At high concentrations it has a slightly pungent odor. Carbon
Dioxide cannot exist as a liquid at atmospheric pressure. Liquefying occurs by
Compression and cooling between the pressure and temperature limits at the triple
Point and the critical point. Above the critical point of 31.C it is impossible to
Liquefy the gas by increasing the pressure above the corresponding critical
pressure Of 73 bar. When liquid under pressure is released to the atmosphere it is

released as a gas and a solid only. This appears as a dense white cloud because of
the solid
Carbon dioxide phase diagram.

And the condensation of atmospheric moisture at the low temperatures obtained.
The solid falls to the ground as snow. The compression of this snow forms a
translucent white solid known as dry ice. As carbon dioxide regulates the breathing
function, an increase in concentration causes an increased breathing rate. The
Occupational Exposure Standard (OES), from EH40, which is updated annually, is
0.5%. However, changes in the breathing rate may not be noticed until the
concentration reaches 2%. At this concentration the breathing rate increases to
about 50% above the normal level. Prolonged exposure at this level for several
hours may cause a feeling of exhaustion and a headache. At higher concentrations
carbon dioxide may cause asphyxiation and can temporarily paralyze the

respiratory system. Breathing in a rich carbon dioxide atmosphere can cause

immediate rapid breath and loss of consciousness. Symptoms of asphyxiation
Can include rapid and gasping respiration, nausea, vomiting, cyanosis and rapid
Fatigue. This may lead to loss of consciousness or death from anoxia. Hence the
Hazards associated with the use of carbon dioxide need to be explained to any
Personnel who may be exposed to it. Carbon dioxide is most important ingredient
in carbonated beverages. For carbon dioxide some standards are there to which the
incoming carbon dioxide has to match.
1. Purity-Must be pure above 99.9%
2. Taste & Odour – Should be normal not pungent or like rotten egg.
3. Snow Test
4. Appearance
Sample is collected from the liquid line of the carbon dioxide tanker as soon as it
is received. The sample is then analyzed as per the authorized testing procedures
provided by the Division in the Carbonated Beverage Quality Control Manual (The
consignment is then either accepted or rejected as per the analysis results.)
TREATED WATER -
Water main & most important ingredient have also some standards
according to Coca-Cola standards. For this regular analysis of water has been done
to check all the quality related parameters.
Treated water used for syrup/beverage production is checked for
• Appearance
• Taste
• Odor
• Turbidity

• P-Alkalinity
• M-Alkalinity
• Total Hardness
• Residual Chlorine at every four hours.
• Iron content is checked once in a day.
OTHER RAW MATERIALS –
• Bleaching Powder & Sodium Hypo chlorite are checked for available
chlorine at each delivery.
• Lime, Ferrous Sulphate, Sodium Chloride, Caustic Soda are checked for %
assay.
• Activated Carbon is checked for moisture content, total ash at each delivery.
• Filter Aid is checked for 10% slurry in distilled water at each delivery.
• Filter Sheets are checked for dimension, GSM at each delivery.
All materials mentioned above are relatively important because they are
used to treat water, for making syrup, CIP purposes.
All parameters are tested according to the Authorized Testing Methods,
Frequencies & Specification for India.
Raw Materials lots not meeting the specification are rejected.
CONCENTRATE AND BEVERAGE BASES:-
Only visual checks for presence of tamper proof seals/damages and

labels are done in case of Concentrate and Beverage Bases.

PACKAGING MATERILS (PRIMARY & SECONDARY): -
NRPET PREFORMS – 50 performs from each lot

Performs are nothing but the incoming PET () Bottles. Perform has been
checked at every lot so meet standards such as
• Weight
• Appearance
• Dimensions
• Height
• Thread go no go gauge
• Neck go no go gauge
• Wall thickness
• Visual checks under sodium vapor & high intensity lamp
CROWN CLOSURE – 50 crowns randomly from each lot

• Weight
• Height
• Go no go trough gauge
• Curve angle trough gauge
• Printing quality
• Out diameter
• Flange angle
• Metal thickness
• Metal hardness
• Line quality

PLASTIC CLOUSER – 50 closures randomly from each lot

• Weight
• Height
• Tamper & evident diameter
• Visual
CANS & CAN END– 50 cans & can ends randomly from each lot from each lot
• Average weight
• Average Height
• Brimful capacity
• Flange width
• Flange thickness
• Wall thickness
• Stand diameter
• Appearance
• Enamel rating
• Body diameter
GLASS BOTTLES – 50 bottles randomly from each lot

• Weight
• Height
• Fill point capacity
• Perpendicularity
• Brimful capacity

CORROGATED CARTONS – 5 cartons randomly from each lot

• Internal dimension (length, width, height)
• Total GSM
• Delamination
• Color
• Wrap page
• Moisture
• Flute count
• Bursting strength
WRAP AROUND LABELS – 5 labels randomly from each lot

• Total GSM
• Dimension
• Joints
• Ink adhesion
• Color
• Winding

MICROBIOLOGY
Microbiological analysis is carried out for assurance of safety of ingredients,
finished product. For microbiological analysis the different types of media used are
as follows
Cc-1 (TGYE i.e. Trypton Glucose Yeast extract): -
For bacterial count by membrane filtration technique.
Cc2 (M green agar): -
For counting yeast and molds in samples by membrane filtration technique.
Cc3 (Endo agar): -
For coli form bacteria in water for one step membrane filtration technique.
Cc4: -
For conformation of presence of E. coli.
General procedure: -
• Sampling
• Preparation of required agar media as per direction
• Sterilization of media.
• Membrane filtration of sample
• Inoculation of media contained in Petri plates
• Incubation at 37ºc in incubator gives total plate count (colony count) after
48, 72 hrs & coli form count after 24 hrs, whereas incubation at 25ºc gives
yeast & mold count.
COMPOSITION OF MEDIAS: -
Cc1:
Casein enzymic hydrolyzate 10 gms/lit
Beef extract 6 gms/lit
Dextrose A 20 gms/lit
Agar 15 gms/lit
Final pH 7 +/- 0.2

Cc2:
Yeast extracts 9 gms/lit
Cerelose 50 gms/lit
Biopeptone 10 gms/lit
Magnesium Sulphate 2.10 gms/lit
Potassium phosphate 2 gms/ lit
Diastase 0.05 gms/lit
Thiamine 0.05 gms/lit
Bromo cresol green 0.026 gms/lit
Agar 15 gms/lit
Final pH 4.6+/- 0.2
Cc3 :
Yeast extracts 1.50 gms/lit
Casein enzymic hydrolyzate 5 gms/lit
Special peptone 5 gms/lit
Tryptose 10 gms/lit
Lactose 12.50 gms/lit
Sodium deoxycholate 0.10gms/lit
Dipotassium phosphate 4.375 gms/lit
Monopotassium phosphate 1.375 gms/lit
Sodium chloride 5 gms/lit
Sodium laurate sulphite 2.10 gms/lit
Basic fuchsine 1.05 gms/lit
Agar 15 gms/lit
Final pH 7.2+/- 0.2
Cc4 :
Peptic digest of animal tissue 10 gms/lit
Yeast extracts 5 gms/lit
Sodium chloride 3 gms/lit
Lactose 12 gms/lit
Bile salts 1.5 gms/lit
Aniline blue 0.1 gms/lit
Agar 15 gms/lit
Final pH 7.4+/-0.2

Sample Sampling point Standards

TPC Y&M Coli
a) Water
1) Well & external well Well water <500/ml <0/100ml
2) Raw water Well water inlet <500/ml <0/100ml
3) Storage tank water Storage tank water <500/ml <0/100ml
4) Treated water ACF outlet <25/ml <0/100ml
Lead ACF <25/ml <0/100ml
Lag ACF <25/ml <0/100ml
5) Treated water After micron filter <25/ml <0/100ml
6) Treated water After UV <25/ml <0/100ml
7) Treated water Raw syrup room <25/ml <0/100ml
8)Treated water Ready syrup room <25/ml <0/100ml
9) Treated water PET/ CAN/ RGB <25/ml <0/100ml
10) Final rinse water PET/ CAN/ RGB <25/ml <0/100ml
11) Warmer solution PET/ CAN <25/ml <0/100ml
12) Tertiary plant water Tertiary outlet <25/ml <0/100ml
13) Decausticiser water After micron filter <25/ml <0/100ml
b) Filling system Filler valves <10/valve <10/valve

Snift valves <10/valve <10/valve
c) Sugar _ 200/10gm 10/10gm

d)Syrup Simple syrup after filtration <5/5ml

Final syrup_ propotioner <5/5ml
e) Washed container RGB <50/ml 10/20ml

PET <50/ml 10/20ml
CAN <50/ml 10/20ml
f)CIP rinse Raw syrup tank <25/ml <10/100ml

Ready syrup tank <25/ml <10/100ml
RGB/ PET/ CAN <25/ml <10/100ml
g) Equipment Hopper of RGB, PET, CAN <50/ml <25/20ml

Seamer <50/ml <25/20ml
h) Finished product RGB <50/ml 10/20ml <0/20ml

PET <50/ml 10/20ml <0/20ml
CAN <50/ml 10/20ml <0/20ml

PROCESS MANUFACTURE:-
WATER TREATMENT PLANT
Water is the main ingredient of carbonated beverages, so it is very important to

check the quality of water for the better quality of final product.
The Multiple Barrier Water Treatment System can continuously produce treated
water and the Softener can produce soft water within Company stated
specifications.
The Multiple Barrier Water Treatment System used to produce treated water for
syrup and beverage preparation. Soft water produced in softener is used for boiler
for steam generation and in washer for container rinsing.

Raw Water From Well

Cl2 Dosing
Pressurized Sand Filter
Raw Water Storage Tank

Ca(OH)2+Fe SO4+CaOCl2
Solid Contact Clarifier(165 m3)
Clear Well

Online CO2 Injection
Treated Water Storage Tank
Activated Carbon Filter
Lead ACF
Lag ACF
10 µ Filter
05 µ Filter
01 µ Filter
Ultra Violet Unit(254 nm)
Process

PROCESS DESCRIPTION -
Raw water is received from the wells through underground pipelines. Chlorination
of water is done at the well site. 3-5 ppm Chlorinated well water is pumped to the
Plant. This water is then filtered through a Pressure Sand Filter and stored in a raw
water storage tank. The raw water from the storage tank is then used for making
soft water or treated water using the respective treatment procedures.
CLARIFIER –
Clarifier is main and most important device in water treatment plant which
clarifies water or in other words it is able to separate all the suspended as well as
dissolved matters from the water.
Solid Contact
Clarifier
Clear Water Tank
Water
Movement
Reaction Zone
Mixing Zone
Impeller
Water+Ca(OH)2+FeSO4
Mother Floc
Sludge Outlet
Raw water from the storage tank is pumped at a constant flow rate
of 30 m3/hr into the centre of the clarifier draft tube of a Solid Contact Clarifier,
with the addition of water treatment chemicals like lime, ferrous sulphate and
bleaching powder in required quantities through dosing pumps. The raw water
entering the central section is distributed over the whole of the area. The raw water

then descends to the bottom of the tank and rises up through the clarifying zone at
a rising rate slow enough to allow the maximum deposition of flocks before
reaching top water level, where the clarified water is decanted through slots in
collecting launder. The collecting launder spans the top surface, thus ensuring an
even rate of draw off from the entire surface of this relatively large area. The
clarified water is then discharged from the collecting trough into the peripheral
launder before gravitational discharge.The clear water is gravitationally discharged
into the Clear Water Tank, and then filtered through Pressure Sand Filters and
stored in the Treated Water Storage Tank. As per the requirement, the water from
the Treated Water Storage Tank is filtered through Activated Carbon Filter to
remove organics and residual chlorine. The water filtered through Dechlorination
ACF is filtered through LLACF and then passed through Polishing Filters of 10
micron, 5 micron & 1 micron in that order, to remove any sand or carbon carried
over and finally passed through an UV Disinfection System for Syrup and
Beverage Preparation, and manufacture of beverage.
PREPARATION OF SOFT WATER:

Raw water from the Raw Water Storage Tank is pumped to a Pressure Sand Filter
in order to filter the sediments. It is then pumped through an Activated Carbon
Filter to remove the residual chlorine. This water is then directed to the top of the
softener vessel. It passes downwards through the Ion Exchanger, the softening
action takes place and the softened water flows from the vessel to the Soft Water
Storage Tank.
Air Bleed
Inlet Water
Activated
Carbon
Coarse Sand
Gravel Layer
Steam Inlet
Outlet
Drain
Activated Carbon Filter

Air Bleed
Inlet Water
Fine Sand
Coarse Sand
Gravel Layer
Gravel Layer
Steam Inlet
Outlet
Drain
QUALITY CHECKS OF WATER-

Color-
Indicates generally the presence of undesirable dissolved, colloidal and
suspended impurities in the water
Examples:
• Iron turns water to brown/red
• Manganese makes it black
• Organics make it yellow
Taste &Odor –
• Indicates generally the presence of undesirable dissolved, such as hydrogen
sulphide or sewage contamination.
• Important parameter for water quality control in the food and beverage
industry.
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
• Suspended solids & colloidal matter make water turbid
• No quantifiable relationship between turbidity & suspended Solids
pH:-
• pH = - log [ H+ ]
• [ H+ ] is concentration of hydrogen ion mole/l
• pH of pure water is 7
• pH scale ranges between 0 and 14, 7 is neutral point
• pH below 7 makes water acidic
• pH above 7 makes water alkaline
Alkalinity
• Indicates the quantifiable quantities of bicarbonates, carbonate and
hydroxide in water
• Determined using Phenolphthalein & screened Methyl orange indicators
• Phenolphthalein gives the P. alkalinity, P.Alk or P value
• Methyl orange gives the M. Alkalinity, M. Alk or M value
• Bicarbonates, carbonate and hydroxide in water are determined from P value
and M value by alkalinity relationships
Total Hardness
• Indicates the quantifiable quantities of calcium and magnesium
• A part of total hardness is associated with alkalinity in water and is known
as alkaline hardness, carbonate hardness or temporary hardness
• The balance of total hardness is associated with no alkaline ions such as
chlorides, sulphates etc. and is known as non-alkaline hardness or permanent
hardness
Total Dissolved Solids

• Indicates total content of dissolved solids in water
• Represents all charged ions – cat ions, anions as well as uncharged and
molecular species
• Summation of cat ions i.e. calcium, magnesium, sodium and anions i.e.
chlorides, sulphates, nitrates and uncharged ions as silica.

Daily Checks of Water: -

• Taste
• Color
• Odor
• pH
• Turbidity
• P- alkalinity
• M-alkalinity
• 2P-M
• Total hardness
• Calcium hardness
• Total dissolved solids
• Iron
• Chlorine
• Micro-organisms- Coli forms

Syrup Making
Quality
Sugar+ Activated Checks
carbon+ Filtering Aid

Clear Plate
1 Hr Contact Filter
Syrup Heat
time at 850C Press Exchanger
Raw Syrup Tank
Up to 200C
Recirculation Precoating
Loop 45 Min. Tank
Raw Syrup Room
Ready Syrup Room
Ready Water addition &

Syrup final 0Bx adjustment
Production Tank
Concentrate Addition

SYRUP PREPARATION –
GENERAL INFORMATION-
Manufacturing of syrup involves preparation of simple syrup, its filtration &
its conversion in to final syrup by adding concentrate or Beverage Base.
Following are the some basic terms which are generally used in preparation
of syrup.
BRIX –
The term was developed by ADOLPH BRIX, a German scientist.
Normally Brix is nothing but “Total amount of soluble solids”
It is generally use to indicate the specific gravity of sugar solutions
ACTIVATED CARBON –
Activated carbon is a carbon in which adsorptive power has been
increased by giving special treatments, Activated carbon is widely
used to remove colour, off taste, & odour producing compounds from
simple syrup.
CONCENTRATE OR BEVERAGE BASE-
Concentrate or beverage base is nothing but mixture of flavours
acidulates& colouring materials produced by the coca-cola company.
Concentrate parts are added to simple syrup to make final syrup.
Raw / Simple Syrup Preparation: As per the syrup batch size the required
quantity of water is taken in the Raw Syrup Tank and heated to 85oC with
continuous agitation.
The required quantity of sugar is weighed and added into the tank and heated to
85oC. Activated Carbon is then added to the syrup along with filter aid for sugar
clarification. A contact time of one hour is maintained. Meanwhile the filter press
is precoated with filter aid. The syrup solution is then recirculated through the
filter press and checked for clarity. Once the syrup is clear it is transferred to a
Sanitized Ready Syrup Tank through a Plate Heat Exchanger where the syrup is
cooled to a temperature below 30oC with the help of water and glycol. The syrup
remaining in the pipelines are pushed to the Ready Syrup Tank with a minimum
quantity of treated water. The syrup in the Ready Syrup Tank is then thoroughly
mixed.
Ready / Final Syrup Preparation: As per the required Flavor and Batch size
Concentrate and Beverage Base in the cold store are brought to ambient conditions
four hours before their addition. Concentrate and Beverage Base are dosed in the
required sequence as per the Master Mixing Instructions. The brix adjustment and
final volume is then made. After proper brix adjustment and deaeration, the syrup is
then ready for production.
Preparation Manufacturing: In case of Preparations, there is no syrup

preparation, due to the absence of sugar in them. Preparations like Kinley Soda
and Diet Coke are made by adding the Beverage Base to the required quantity
of water directly to the final syrup tank, as per their respective Master Mixing
Instructions.
Simple syrup storage- Simple syrup storage is restricted if there is any major
failures in operation, so that concentrate addition is not possible immediately
after the simple syrup preparation. Simple syrup (60 Degree Brix and above)
can be stored up to 24 hours.

Beverage Manufacturing in PET & CAN

Raw Water
Sugar + Filtering aid + activated
Carbon@850C for 1 hr.
Coagulation System
Raw Syrup Sand And Carbon Filters
10µ ,5µ ,1 µ Filters

addition of concentrate
UV Treatment
Ready Syrup
Treated Water
Paramix Operations
Dearation and mixing of

water with ready syrup
Chilling in PHE
Carbonation
Chilled carbonated
beverage buffer tank
Rinse CAN/PET with water (1-3 ppm Cl2)
Beverage Filling
Capping with Closure

(PET) / lid (CAN)
Date Code Application
PET/CAN warming
Labeling (PET)
Casing
palletizing
Warehouse

PLASTIC BOTTLES
Advantages And Limitations
Consider these differences with glass bottles.
Advantages
1. Plastics are lighter in weight when compared with glass; for example a
typical 1 l PET bottle weighs 38 g, against a 1 l glass bottle of 600 g.
2. No corrosion problems when compared to cans.
3. Versatility in design terms.
4. 4. The offer of a larger pack format, for example a typical PET bottle is 2 l
in size, the largest glass bottle offered for soft drinks is 1.1 l, and
dimensionally they would appear similar in size.
5. Impact strengths can be greater than glass and where breakages do occur
there are no splinters.
6. Quietness in use in the bottling plant.
Limitations
1. Plastics are not complete barriers to either gases or water vapor, this means
Carbonation can escape and oxygen ingress can occur over time.
2. Some chemicals attack plastics; for example silicone sprays, often used to
lubricate conveyors, can induce stress cracking in PET bottle bases.
3. Resistance to abrasion can mean a poor bottle surface appearance,
particularly if returnable plastic bottles are being considered.
4. There is a potential liability for the build up of static electricity, which can
give rise to two key issues in terms of soft drinks bottling. First, if a bottler
blows their own bottles on site then bottles may stick together on the air
conveyor system on route to the filler causing intermittent supply. Second,
if the bottles are pre blown or preforms used for bottling on site are not
100% clean then static can attract minute particles of dust which may coat

the internal surface of a bottle causing product to fob during filling.

5. When comparing plastic and glass bottles of the same volume then visually
the plastic bottle will look smaller giving a consumer the perception of
getting less.
Polyethylene terephthalate
Polyethylene terephthalate (PET) is a polyester polymer consisting of
alternate units of ethylene glycol and terephthalic acid. The chain length is about
30,000 double units, depending on application. PET used for carbonated soft
drinks has a different requirement to that used for still drinks.
History
PET was developed as a textile fibre in the 1940s and is still used as such for
carpets and clothing. Its use in packaging was initially in the mid-to-late 1960s for
packaging films. The use of PET for carbonated soft bottles started in the early part
of the 1970s, when it was first introduced as a bottle that comprised of two parts.
The main body section, which contained the product, had a cylindrical body
section with rounded shoulders and a hemispherical base. In order that the bottle
could stand up, a base cup, usually black and made from high density polyethylene
(HDPE) was stuck to the hemispherical bottle base with hot melt adhesive. The
main disadvantage of the two-piece bottle was the fact that gluing of the bottle and
base was a critical aspect of the process which was often its weakest link in terms
of final pack quality. Those first bottles weighed about 65 g excluding the base,
which compares with today’s modern five foot petaloid 2 l bottle which weighs
only 43 g.

POLY ETHYLENE TEREPTHALATE

PET Raw Material
Crude oil Refinery
Catalyst Antimony or
Germanium
Ethylene Glycol (EG)

+ + Liquid
Terephthalic Acid
(PTA) or Dimethyl
Terephthalate
(DMT)
White Powder Packaging
It is a product of petrochemical industry.

• 1941 Discovery by British Petroleum
• 1952 First commercial application (textile fibres)
• 1954 FDA acceptation for food contact
• 1955 Dupont R&D on PET bottles
• 1973 Dupont license for PET bottle
• 1975 First test market in USA
• 1976 FDA acceptation for PET bottle
• 1987 First hot fill application
• 1988 First Refill bottle production
• 1989 Multilayer PET preform
• 1997 Coated bottles
For PET Bottles performs are used which have their own specifications for
different package size.
600ML : 27 gm
1.5/2 liter : 48gm
1. 25 liter : 39 & 44 gm
Desired preform size according to the SKU size is blown in a SBO-8 machine
using compressed air.
• The preforms are unloaded in the preform hopper.
• Then preforms are elevated to the blowing machine with preform
elevator
• The preforms are heated with help of an IR oven to the required
temperature as per the recipe selected.
• The heated preforms are fed into the water-cooled mold with rotating
arms.
• In an operating cycle the preform is first stretched using a stretch rod,
preblown as per recipe desired and finally blown with 40 bar air
pressure and simultaneously cooled
• The blown bottles are carried out to the filler (rinser) with the help of
air conveyer.
PET FILLER
• The bottles are firstly rinsed with chlorinated treated water.
• There after the bottles are filled with the beverage supplied by the Para
mix
• The filled bottle is transferred to the capper and sealed with the closure
• After filling and capping, the bottles are coded.
WARMER & LEBELLER

• The filled bottles are passed through the warmer to bring the
temperature to room temperature for proper packaging
• The bottle is passed through the labeling machine for application of the
desired label.
• The labeled bottle is packed in a carton using a caser machine and
packed with top sealer.
• Sealed cartons are then carried out through a case conveyer coded with
a box coder machine and finally go to the palletizer where it is stacked
on pallets in desired sequence.
• The pallet is then transferred to the Warehouse for storage, by means
of a forklift.
1. The shrink-wrap on the empty can pallet is removed and any dented can bodies
found are rejected.
2. The pallet is then loaded on to the platform of the Depalletiser.
3. Each layer of cans is transferred onto a conveyor, wherein they form a single file
onto a rope conveyor.

4. The cans then pass through a Can Rinser where they are rinsed on the inside
with chlorinated treated water containing a chlorine residual of 1 – 3 ppm.
5. The cans then enter the Can Filler where beverage is filled into the cans.
6. Carbonated beverage is prepared as per the specified syrup and water ratio in the
Propotioner.
7. The prepared beverage is then chilled and carbonated as per the product
carbonation specifications.
8. The beverage is then filled in the cans at a maximum speed of 1100 cans per
minute.
9. The filled cans then enter the Seamer where the exposed beverage in the can is
subjected to CO2 cover gassing before the lid/end is placed on the can and
sealed/seamed.
10.The seamed cans then pass through a Can Warmer where they are exposed to a
hot water spray at about 40oC. This is to avoid condensation on the can surface and
thus help in proper can coding and prevent cartons getting wet after packing.
11. An air blower at the Warmer exit blows off water on the base of the cans.
12. The cans then pass through an air jet to remove moisture on its base. They are
then coded on the base using a high speed ink jet coding machine.
13. They then pass through a Fill Height Rejecter where cans with fill volume less
than the set standard are knocked off the conveyor into a Fill Height Rejects bin.
14. Only cans with fill volume within specifications are conveyed to the packing
machine.
15. The packing machine, Meypack, is fed with cartons on one side and cans on
the other side.
16. The cases are then coded on the side flap with the Manufacturing Week
Number and the Price.
17. These cases are then conveyed to a Palletizer where they are systematically
stacked on to a wooden pallet (110 cases per pallet).
18. The pallet is then transferred to the Warehouse for storage, by means of a
forklift.
ON LINE CHECKS OF CAN:-

1. Brix by densitometer (DMA)
2. Gas Volume
3. Net Content
4. Seaming Parameters
5. Air Content
6. Appearance, Taste and odor

CARBONATION
Basic considerations
If we consider a liquid–gas mixture in a sealed container, the state of
equilibrium is said to exist when the rate of gas leaving the liquid solution equals
that entering it. If you take any PET bottle of carbonated soft drink and shake it,
the liquid gas interface will initially fob. However, after a short while, the
equilibrium condition will have been reached and the liquid will be quiescent. If
the cap is then opened and some of the contents poured out, the cap replaced and
the procedure repeated again, it will be noted that before shaking the bottle is limp
but after shaking it becomes hard. In this process gas has come out of the solution
to attain the equilibrium condition. This state is just stable. Any decrease in
pressure, or increase in temperature, will render the mixture metastable, that is,
supersaturated, such that the temperature/pressure combination is insufficient to
keep the carbon dioxide in solution. If this occurs then the gas is spontaneously
released giving rise to fobbing. If the mixtures were agitated or some irritant, such
as small particulates added to the mix, then the rate of gas release will be even
more pronounced. This is due to nucleation sites being generated by the presence
of these particulates or other gases, such as air. Any carbonated product that is held
in a container that is open to the atmosphere will gradually lose carbonation. This
is due to the gas being liberated to the atmosphere as the liquid/gas interface
continually strives to achieve the equilibrium condition. In a closed container the
gas fills the container headspace, thus increasing the headspace pressure. This
happens quickly at first and then slowly as equilibrium is approached. The rate of
transfer of gas from the product to the headspace depends on the proximity of the
headspace pressure to the equilibrium pressure, the temperature of the liquid, the
nature of the beverage, the extent of any agitation and the presence of any irritants.
A quiescent, stable product will take many hours to reach equilibrium when not
subjected to any external forces such as agitation, movement,
temperature or pressure change. However, the same product roughly shaken will
only take seconds to achieve the equilibrium condition. The faster the rate of
change towards the equilibrium condition the sooner this condition will be reached.
For a given volume, the amount of carbon dioxide which a solution can maintain
depends on the temperature and pressure. The higher the temperature the greater
the pressure required to maintain the carbon dioxide in solution. Conversely, the
lower the temperature the greater the amount of carbon dioxide that is retained in
solution. Henry’s law was postulated by William Henry (1774–1836) and states,
‘The amount of gas dissolved in a given volume of solvent is proportional to

the pressure of the gas with which the solvent is in equilibrium’, whilst Charles’
law (1746–1823) states, ‘The volume of an ideal gas at constant pressure is directly
proportional to the absolute temperature’. These two laws can be combined to form
the universal ideal gas law:
where p is the absolute pressure, V is the volume, m is the number of moles

of gas, R is the gas constant (for that particular ideal gas) and T is absolute
temperature. A mole is that quantity of a substance which has a mass numerically
equal to the molecular weight of the substance. For carbon dioxide the molecular
weight is 44.01 and R is 0.18892 J/mol K. From this

relationship the carbonation chart shown in Figure can be deduced. Here the
concept of carbonation volumes is introduced. Volumes ‘Bunsen’ is where the gas
volume is measured at atmospheric pressure (760 mmHg) and the freezing point of
water (0.C). It is defined as the number of times the total volume of dissolved gas
can be divided by the volume of liquid in the container. As an example, a product
with four volumes carbonation will contain carbon dioxide to the extent of four
times the volume of the beverage. A 1 l container carbonated to 2.5 volumes would
contain 2.5 l of carbon dioxide, and likewise a 3 l container carbonated to 4
volumes carbonation would contain 12 l of carbon dioxide. One volume ‘Bunsen’
is equivalent to 1.96 g carbon dioxide per litre. This is often simplified to 2 g/l. For
PET bottles normally, the smaller the container the higher the carbonation
volumes. As the rate of loss of carbon dioxide by permeation due to a high surface
to volume ratio is large. Shelf life is normally defined as 15% carbonation loss in
12 weeks, which a 2 l bottle can easily meet. This will reduce to ca. 9 weeks for a
500 ml bottle and some 7 weeks for a 250 ml bottle. The light weighting of PET
bottles gives rise to thinner wall thicknesses and hence greater permeation and a
shorter product shelf life. Cans have carbonation levels up to 3.5 volumes. Any
higher internal pressures that can be generated during expected use would cause
can rupture to occur. Glass bottles can be designed to accommodate higher
pressures, such as tonic water which is traditionally a high volume carbonation
product, dependent on design and wall thickness.

CARBONATION MEASUREMENT
This is measured using a device similar to that shown in above figure. It

consists of a jig in which the container can be restrained and a piercer which,
when used to pierce the container, allows the gas pressure to be read. The container
is placed in the jig and is first of all pierced, then shaken, before the pressure is
measured. The release valve is then opened until the pressure gauge reads zero and
all the gas has been exhausted from the container headspace. The release valve is
then closed and the container shaken again. The pressure is retaken. The container
is released from the jig and the temperature of the contents taken. The carbonation
chart is then used to determine the volumes of carbonation. Why do we need to go
to the extent of releasing the pressure from the container before we take the
pressure reading? The problem is air inclusion in the beverage. This gives a twin-
gas system of air and carbon dioxide. It is necessary to first release the air to
determine how much carbon dioxide is present. Air is approximately one-fiftieth
the solubility of carbon dioxide in a liquid. Hence any air contained within the
beverage will exclude some 50 times its own volume of carbon dioxide. The Law
of Partial Pressures was postulated by Jon Dalton (1766–1844) as ‘the pressure P
of a mixture of gases that do not chemically react is equal to

the sum of the pressures of the individual constituents when each occupies a
volume equal to that of the mixture at the temperature of the mixture’. This can be
written for a mixture of N number of gases as
The partial pressure of a constituent gas in a mixture is equal to the product

of the total pressure and the mole fraction (X) of that gas in the mixture, that is,
where i corresponds to an individual component. the mole fraction X being

a method of expressing the composition of a mixture
Air is primarily made up of 79% nitrogen and 21% oxygen, ignoring for
simplicity the presence of the inert gases. In any carbonated mixture we will have
carbon dioxide, nitrogen and oxygen present. Due to the differing solubility and
proportions of oxygen and nitrogen, the dissolved air actually contains 35%
oxygen and 65% nitrogen as the solubility of nitrogen is low. It is this enrichment
of oxygen that can give rise to spoilage problems with the product if care is not
taken to minimize the amount present. The presence of air will also give rise to a
higher pressure and hence a false reading of the volumes carbonation from the
carbonation chart. The amount of air present clearly has to be minimised when
taking carbonation measurements. If we consider a bottle with a gas headspace of
5% of the bottle volume, on the first snift the gas loss would be 5% of the bottle
volume. On the second snift we would lose a further 5%. If only carbon dioxide
were present in the headspace we would expect to lose 5% pressure on the first
shake and some 7% by the second shake. If other gases were present we would
lose more pressure. Thus the amount of air present in the product can also be
estimated during carbonation measurement. If excess air is

found then actions need to be taken to minimise its presence. The problem is often
caused by air entrainment or poor sealing with the filler bowl. This can be seen
from an example where by volumetric analysis it has been found that the
headspace of a carbonated drink container contains 90% carbon dioxide, 3.5%
oxygen and 6.5% nitrogen.

FILLING PRINCIPLE
The first criterion that needs satisfying is to seal the container, whether it is a
glass bottle, plastic bottle or can, to the filler bowl such that no leakage can exist
via the seal. The filler bowl is filled to a given level, which by means of float
valves is maintained within close tolerances. This ensures a near constant pressure
head during the filling process, an important factor if constant flow conditions and
repeatability are to apply. As shown above figure, once the container is sealed to
the filler bowl we can open valve to allow filling to commence. The gas within the
container, which for carbonated products is normally carbon dioxide though
nitrogen can be used, needs to exhaust somewhere as the liquid filling the
container displaces the gas. This is achieved by means of a vent tube, the rate of
flow of liquid into the container being proportional to the rate of flow of gas
displaced. When the liquid reaches the vent tube it will start to fill this until such
time as the pressure within the vent tube equates to the filling tube pressure. When
this equilibrium condition is achieved the liquid flow will stop. Then the filling
valve is closed. Following this the container can be lowered
from the filler bowl. During this process the liquid within the vent tube will drain
out that left in the vent tube due to surface tension effects dependent on the
characteristics of the liquid being filled. The process cycle is shown in below
figure .A bottle have a standardized neck finish to allow it to seal effectively at all
times with the filler bowl and this finish must be produced to a minimum standard.
It also have sufficient top load to withstand the forces involved during the filling
process. Bottle filler lifts PET bottles by the neck to overcome deformation
problems during the process. This also allows light weighting of the bottle, which
is advantageous for both environmental and commercial reasons. To achieve
commercially acceptable filling speeds fillers are rotary (RGB & PET).
Bottles are fed into the filler by conveyor to an in-feed worm and star-wheel
in single file. This star-wheel incorporates a air pressure-operated bottle stop which
stopped the bottle stop in emergency will engage automatically. From the star-
wheel the bottles are fed to a bottle-lift stirrup, sited below an individual filling
valve, and lifted by the neck to the seal with the filler bowl. RGB filler use bottle
lift on which the bottle rests, and then lifted to seal with the filler bowl. The filling
valves are sited at equal intervals around the base of the filling.
SCHEMATIC DIAGRAM OF BOTTLE FILLING
Spray Jets
FILLING PROCESS
FILLER
COUNTER PRESSURE
Value Closing Lever
Value Closing Lever
Value Opening Lever Snifting
Bottle infeed Bottles to Crowner

RGB Line Inplant Training at Coca-Cola

BEVERAGE MANUFACTURE IN RGB
Empty Refillable Glass Bottles in crates are manually transferred onto a conveyor,
leading to the De-crater/Uncaser.
. The Uncaser empties the crates by lifting the bottles and transferring them
onto another conveyor.
. The empty crates are conveyed to a Crate Washer where the crates are
washed with hot water recycled from the Warmer/Hydro wash compartment of
the Bottle washer.
The empty bottles then pass through an Inspection station known as the
Prewash Inspection Station. Here very dirty bottles that are difficult to clean in the
bottle washer, foreign bottles and broken bottles are rejected.
These bottles then enter the Bottle washer where they are washed using hot
caustic solution and rinsed with water using stationary and rotary jets. The bottles
are finally rinsed with chlorinated soft water (1 – 3 ppm residual. chlorine) before
they exit the Bottle washer.
BOTTLE WASHER
Recent years, consumer awareness and regulatory demands have

emphasized the need for soft drinks to be packaged in clean, commercially sterile
containers .The purpose of container washing and rinsing is to provide clean and
commercially sterile containers that are ready to be filled. The bottle washing
operation must remove all dirt and foreign matter from the inside and out side of
returnable bottles, and bottle washing conditions (caustic concentration,
temperature, and contact time) must kill yeast, molds, and pathogenic bacteria, thus
producing commercially sterile bottles free from residual detergents. Before in feed
to the bottle washer, the prewash inspector removes all unacceptable bottles, such

as those that are chipped or cracked. Broken bottles can cause machine stoppages,
and glass shards can accumulate at the bottom of the washer’s soak tanks,
interfering with bottle flow.
The inspector also rejects foreign bottles as well as unclean able bottles,
such as those covered with paint, concrete, or grease.
Bottle washing equipment design
Bottle Washer Structure
Bottles In Bottles out

Hydro Section
Final Rinse
Pre-Rinse
Soak-2
PreFinal-2
Soak-1
PreFinal-1
Bottle washing equipment needs to produce commercially sterile bottles.

Specifically, effective equipment will: Remove all dirt and foreign material from
the inside and outside of refillable bottles. Maintain washing conditions( caustic
concentration ,temperature, and contact time).Completely rinse all traces of
residual detergents from the bottles
Bottle washer Cycle
Usually bottle washer consists of following cycles
1. Pre-wash
2. Soake
3. Hydro
4. Pre- final rinse
5. Final rinse
Hot caustic Treatment in Soak Compartment
The bottles are subjected to undergo the process of hot caustic Treatment in
soak compartment. The material needed are
• Water
• Steam
• Caustic Flakes /Lye
• Additives
Water
• Caustic solution in Soak Tank should be prepared in soft water only. The
soft water used to avoid
• Improper Washing
• Scaling
• Damage to the Heating Coil
• Loss of Heat
• Corrosion
Steam
• Steam is supplied in to the soak tank through heating coil
• The steam should be regulated to raise the caustic solution temperature to
the standard range .As a result chemicals are activated to clean the bottle
effectively.
Caustic
Caustic is used as a Washing agent & it acts as follows
• Soluble in both hot & cold water
• Emulsifies the fat content
• Swells & Hydrolyses the protein

• Dissolves the Carbohydrates

• Disperses in soluble matters
• No trouble for bottle washer lubrication
• Non -Abrasive in nature
• Low foaming
• Better fluidity.
Additives
o The additives contains following
o A sequestering Agent
o An wetting Agent
o Defaming agent
o Corrosion Inhibitors
Sequestering is defined as the suppressing the property or reaction of a metal
without removing that metal from the system or phase by the process of
precipitation.
These are Non -ionic surface-active agents having detergent nature.
• By lowering down the surface tension of the bottle washer solution.
• It penetrates the soiling materials
• It acts as a catalyst for reactivity of caustic solution
Defoaming agents are added to the caustic solution to
• To increase the effectiveness of the cleaning
• To avoid the loss of the detergent solution-For operational safety
Corrosion takes place by

• Scale Formation
• Removal of the Metal ions

So to avoid this type of corrosion, Corrosion inhibitors like Phosphate salts of

Methylene Phosphoric Acids is added.
PARAMIX
It is the Proportioning Equipment wherein the Ready Syrup and the Treated
Water mix, in a definite ratio, along with CO2 as per the Gas Volume requirement,
by setting (temp. & pressure) for a particular flavor.
FILLER –
• Here empty bottles are filled by using isobaric gravity flow with a regular
speed of 600 bottles per min.
• Crowning done after filling process.
DATE CODING
• The crowned bottles are then coded on the bottle neck with the
manufacturing date, time and price.
• These bottles then pass through a Final Inspection Station where bottles
without proper fill level, date code, or crowns are rejected.
• These bottles are then transferred into crates with the help of Caser/Crater.
• The filled crates are then manually palletized and transferred to the
Warehouse for storage.
ON-LINE QUALITY CHECKS
Sampling and Testing Frequency of final product-

The finished product (carbonated beverage) sampling and testing frequency,
as a minimum requirement is as stated below:
Taste Test (all types of containers)
• At start up

• First product
• After 30 minutes
• End of run/batch
• At product changeover
• Appearance (all types of containers)

o At start up
o First product
o After 30 minutes
o End of run/batch
o At product changeover
• Brix/ratio adjustment (all types of containers)

o At start up
o First product
o After 30 minutes
o End of run/batch
• Carbonation (all types of containers)

o At start up
o First product
o After 30 minutes
o End of run/batch
• Net Content (all types of containers)

o At start up

o After 30 minutes
o At package changeover

• Crown Crimp (Glass)

o At start up
o Every 4 hours
• Date Coding (all types of containers)

o At start up
o After 30 minutes
• Closure Torque (Glass and PET)

o At start up
o Every hour
• Proper Application Test (Glass and PET)

o At start up
o Once per shift
• Can Seam Evaluation (Cans)

o At start up

o Every 4 hours
• Air Content (Cans)

o At start up
o Every 30 minutes

CLEANING IN PLACE
Cleaning and Sanitation –

Cleaning is nothing but the washing of the equipment to remove all
unwanted material, where as Sanitation is the treatment of cleaning surfaces and
equipments by a process that destroys pathogenic bacteria and substantially reduce
the population of all other micro-organisms. Cleaning solutions used in food
industries are most commonly aq.solution of biodegradable alkaline detergents.
The cleaning agent should be based on caustic soda or tri sodium phosphate.
CIP-
It is the cleaning and sanitation system where detergents and sanitizing
agents with water are circulated through the equipment and lines by pumping or
spraying .In 3 step CIP first water is circulated through the lines after circulating
water all lines are sanitized with CIP chemical till all caustic residual is removed
from line
CIP means Clean-In-Place is used to describe the cleaning and
sanitizing system where detergents, sanitizing agents and water are circulated
through equipment and lines. Unlike the soaking or flooding system, circulation is
accomplished by pumping or spraying (using a spray ball) solutions from solution
holding tanks through equipment, and then in many cases returning it to holding
tanks. This allows equipment and lines to be cleaned and sanitized in place without
being dismantled. The system also allows for maximum economy when solutions
are reused.
3 Step is followed in plant contents pre-rinse, chemical circulation & final
rinse.

BOILER SECTION
Boilers are used for generating steam, which is used for various purposes in the
industry.
”A steam boiler is a closed vessel in which a steam or vapor is generated for
the external use by direct application of heat produced from the combustion of
fuel(solid, liquid, gases) or by the use of electrical energy.”
In our context the boiler is required for producing steam, which is used for
the following-
Heating caustic/ water in the bottle washer

Dissolving and pasteurization of raw syrup
Heating of water for CIP system
Degassing and sanitation of activated carbon filters.
For evaporators in CO2 bulk storage tank
Heating of water for floor washing
For warmer of PET and CAN
A steam boiler is a closed vessel in which the steam or other vapors are
generated for the external use by the direct application heat produced from the
combustion of fuel. Boilers are two types “water tube” boiler in which water
passes through tubes and hot gases surround it, “Fire Tube” boilers the hot gases
passes through the tube and water surrounds it.
Heat is transferred through the hot gases to the water via the metallic tubes
in between them. After giving the heat to the heater the hot gases are exhausted
through the chimneys in to the atmosphere. In HCCBPL.Pune industry the heat is
utilized for the heating of incoming air. The steam formed from the water is taken

out through stem pipes to different required areas. The make up water is added as
per the requirement by multistage pump and the boiler is blown after Suitable
interval to remove the seals and other salts from it. (Above 2350 ppm) and the
other auxiliaries are also added to the boilers for its efficient use like stop valve,
pressure reducing valve, steam trap, steam separate etc components.
Components
• Steam Boiler
• Feed water pump
• Oil gear pump
• Feed Water Tank
• Oil tank
• Make-up tank
• Molding unit
• Pneumatic blown down valve
• Chimney
• Pressure reducing valve
• Steam separator
• Non-return valve
• Stop valve
• Steam trap
HCCBL has 3 pass fire tube boiler means the hot gases blown from the one of the
boiler to the other end three times. This is done due to increase the contact time
between water and flue gases. The bagass boiler consists of combustion of bagass
and hot gases produced are then circulated through boilers.
Plant steam requirement is 2 kg for Raw Syrup and 3 kg for bottle washer.
And plant boilers have capacity of 5 TPH each.

Feed water should have following specifications-

• pH should be > 4.5
• Hardness should be less than 5ppm
• TDS should be less than 500 ppm

REFRIGERATION SECTION
Refrigeration is a transfer of heat from a place, where it is not desired, to place,

where it is unobjectionable.
Use of refrigeration in plant-

Refrigeration system is required for the following purposes in plant. Such
as-
• Beverage cooling in the buffer before filling
• Raw syrup cooling
• Air conditioning of labs, micro-labs, offices.
• Maintaining low temperature in the concentrate storage room.
• Chilling of water mix with syrup in paramix before carbonation.
Flow of heat in plant-

1. from beverage/ raw syrup to propylene glycol-
Cold glycol is circulated through the heat exchangers by the
secondary pumps. In the beverage PHE the heat of the beverage absorbed by
propylene glycol flowing in opposite side to beverage. Similarly in the raw
syrup cooler heat is transferred from raw syrup to propylene glycol.
Hot propylene glycol goes to the hot well of the tank of the refrigeration
tank room.
2. from propylene glycol to ammonia

The glycol from the hot water well is circulating through the chillers
by the primary pumps. The glycol gets chilled in chillers by transferring heat
to the boiling ammonia on the other side of chiller.

The chilled glycol returns to the cold well of the tank.
3. from ammonia to the cooling water

Ammonia gas from the chiller is sucked by the compressor and
compressed to the high pressure. High pressure ammonia gas from
compressor goes to the condenser via oil separator. Heat input in the form of
electrical energy (power consumed) is added to ammonia in compressor,
where it get compressed.
In condenser the ammonia gas is condensed by cooling water and high
pressure ammonia liquid is drained ti ammonia receiver. The heat picked up
from the glycol as well as electrical input gets transferred to cooling water.
Ammonia liquid from the receiver goes to the glycol chiller. High pressure
liquid passes through expansion valve where it is expanded to low pressure
liquid before entering the chiller. The liquid ammonia is evaporated into the
heat exchanger there by cooling glycol.
3. From cooling water to atmosphere

The cooling water heated in the condenser is sprinkled in the cooling
tower where the heat from the water is transfer to air flowing in a reversed
direction. The transfer of the heat takes place by the evaporation of small
amount of water and saturation of the air.
The water gets cooled again circulated by pumps through condenser. thus
the heat from beverage/ raw syrup where it is undesirable is ultimately given
to the atmosphere by using refrigeration system.

Major components of refrigeration system -

• Compressor
• Condenser
• Expansion device
• Evaporator
For beverage application food grade propylene is used being non poisonous
also contamination by maintaining positive pressure of beverage in system.

HCl /NaOH & Urea, DAP
Aeration Tanks
Secondary
Incoming Splitter
Clarifier
Effluent ETP Collection Equalization Tanks Chamber
from Plant Sump
Cl2
Gardening &
Fish Tank
Softener
Micron
Filter
Flash Mixer
PSF
PSF Pump
Tertiary (FeSO4
Clarifloculator
Water UV Unit Dosing)
Sump
Cleaning Sludge Holding

Tank
Dried Sludge Drying Bed
Sludge
Effluent Treatment Plant

EFFLUENT TREATMENT PLANT:-

Effluent treatment plant or in short ETP is one of the major and important
areas in the bottling plant. Its major function is treating of the effluent generated in
the plant operations. Effluent can be defined as anything that effects our
environment causing harm where environment is the surroundings where we live in
(air, water, nature etc.). The major characteristics of the effluent generated are as
follows:
High pH
High TDS
High TSS
High COD – Chemical Oxygen Demand
High BOD – Biological Oxygen demand
Oil and grease
This effluent if released in the atmosphere into a pond or lake) will cause
damage. The BOD in the effluent will result in the microorganisms to take
dissolved oxygen from water and grow. Thus the DO level in water decreases
causing danger to existing aquatic life. These die and cause a condition of septic in
water. This causes generation of many nutrients which result in growth of shrubs
and trees. All this results in the depletion of the water body, a condition called
Eutraffication. The plants so grown are rich in chemicals such as iron etc. which
were earlier dissolved in water and if consumed by animals will cause
accumulation of heavy metals in their body. This condition is called bio-
magnification. Thus the release of untreated effluents to water bodies destroys the
complete eco-cycle. To avoid all these unwanted results, it is necessary to treat the
effluent before releasing it into the environment.

Definitions:
Biological Oxygen Demand (BOD): It is the amount of oxygen consumed
by microorganisms in order to utilize the biodegradable matter present is the
sample when incubated for 5 days at 20oC, Oxygen demand for Microorganisms
Chemical Oxygen Demand (COD): It is the amount of oxygen consumed
by potassium dichromate in presence of Conc. Sulphuric acid heating at 140oC for
3 hours, Oxygen demand for Chemical Oxidation
The effluent basically undergoes primary, secondary and tertiary treatments.
Considering the importance of conservation of natural resources, the treatment
system is designed to treat the effluent up to the reuse standards of water for
secondary process applications. Primary treatment involves separation of floating
matter, oil and grease. The secondary treatment processes involved are
equalization, neutralization followed by two stage biological treatment consisting
of anaerobic-aerobic processes, in which importance is to conserve electrical
energy and recover non-conventional energy source, i.e., biogas. The tertiary
treatment involves sedimentation and filtration for suspended solids removal,
activated carbon filtration to control organic load and removal of contamination
using pre and post disinfection by chlorination and UV system. The waste water
generated from process, wash, utilities etc. is collected in a collection tank after
passing through a bar screen chamber and oil and grease trap where suspended
matter like straws etc. are removed in bar screen and floating oil and grease are
removed by skimming in oil and grease trap. Wastewater from the collection tank
is pumped alternatively into one of the two fill and draw type equalization cum
neutralization tanks. These tanks are used alternatively i.e. one tank is filled first
and then the flow is diverted in to the second. Waste water in the first tank is
equalized both quantitatively and qualitatively using neutralizing agents such as
lime or acid as per the requirements. Neutralizing agents are prepared in the dosing

tanks. Floating aerators are provided in the neutralization cum equalization tanks to
ensure thorough mixing.
This homogeneous mixture of wastewater is pumped into the anaerobic
tower where it is treated in the absence of air. Further the water is pumped to the
aeration tank where it is biologically treated in the presence of air. Aerators are
provided in the aeration tank to ensure necessary DO levels. The wastewater from
the aeration tank flows to the secondary clarifier where the MLSS settles down in
the form of sludge. The settled sludge is recycled to the required extent to maintain
MLS concentration in the aeration tank and the excess sludge is drained on to the
sludge drying beds for dewatering and drying.
The secondary treated effluent is collected in a collection/chlorination tank
where chlorine is dosed. The chlorinated effluent is then pumped to the chemical
treatment tank where coagulation/flocculation of suspended solids occurs. This
water is now sent to the lamellar clarifier for removal of suspended solids.
The clarified effluent is then collected in intermediate sump and pumped
through the PSF for further polishing. The effluent is then passed through the
activated carbon filter for removal of residual organics. The effluent is passed
through the UV disinfection system.
The new UF-RO system includes treating this water to higher levels of
purity. Here the water at the outlet of ACF is stored in a tank and sent to Ultra
filtration unit from where it passes through the RO unit where permeate is stored in
the permeate tank. This is further passed through the softener and water is then sent
to the soft water storage tank.

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Inplant Training at Coca-Cola

INPLANT TRAINING REPORT

A.P - Pirangut, Taluka-Mulshi

PATKI PRASHANT JANARDAN

In the partial fulfillment of the

MARATHWADA AGRICULTURAL UNIVERSITY.PARBHANI

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

I have undergone Three Months In plant Training at HINDUSTAN COCO-

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

• First plant commissioned by TCCC in India- 1996

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

Arrival of COKE in India….

College of Food Technology, Parbhani.

The world’s favorite drinks and most valuable brand. Cola

College of Food Technology, Parbhani.

Water, a thirst quencher that refreshes a life giving Force that

College of Food Technology, Parbhani.

Worldwide Sprite is ranked as No.4 soft drinks and is sold in

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

FLAVOURS MANUFACTURED AT PUNE UNIT

IN RGB (200ML & 300ML)

IN PET (600ML, 1.25LTR, 1.5LTR, 2 LTR)

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

Area General Manager

Quality assurance Techno-Commercial Production/Maintenance

QA Executives Microbiologist Production Maintenance

PET/CAN line Team Leader Team Leader

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

DETAIL OF PRODUCT MANUFACTURE…

ABOUT SOFT DRINKS:-

SOFT DRINK INGREDIENTS:-

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

1. FOR NON-DIET SOFT DRINKS:-

DIET SOFT DRINKS:-

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

RAW MATERIAL SAMPLING PLAN & TESTING PROCEDURES

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

College of Food Technology, Parbhani.

Carbon dioxide phase diagram.

College of Food Technology, Parbhani.

respiratory system. Breathing in a rich carbon dioxide atmosphere can cause

College of Food Technology, Parbhani.

CONCENTRATE AND BEVERAGE BASES:-

Only visual checks for presence of tamper proof seals/damages and

College of Food Technology, Parbhani.

PACKAGING MATERILS (PRIMARY & SECONDARY): -

NRPET PREFORMS – 50 performs from each lot

CROWN CLOSURE – 50 crowns randomly from each lot

College of Food Technology, Parbhani.

PLASTIC CLOUSER – 50 closures randomly from each lot

GLASS BOTTLES – 50 bottles randomly from each lot