28/07/2014

INDUSTRIAL TRAINING REPORT

On
QUALITY CONTROAL AND MENUFACTURING FOR CSD &
NCB BEVERASES
PepsiCo India Holdings Pvt. Ltd. , Bazpur

Submitted To

Mr. Nitesh Jain

Quality Assurance Manager
PepsiCo Bazpur

For The Partial fulfillment of the Degree of

Bachelor of Technology in Biochemical Engineering

Submitted by

IMRAN AHMED
B.Tech 6th semester
Bipin Tripathi Kumaon Institute of Technology,
Dwarahat

ACKNOWLEDGEMENT
It is said that behind any accomplishment of any effort there are some
dedicated individuals who put in their best to get the job done.
I also want to express my full thanks to Mr. D. K. Singh (A.M.), Mr.

Praveen Shukla Executives Mr. Pravendra Singh (microbiologist) for

giving me their support during my training period in this industry.
Finally we would like to express my wholehearted thanks to Mr. Nitesh Jain
Manager Quality, PIHP ltd. (Bazpur) for providing this excellent opportunity
and a co-operative environment along with guidance and constant
encouragement and helpful discussion throughout our training.
Last but certainly not the least I am highly grateful to all supporting staff of this
industry for their sincere cooperation. I am sincerely indebted to them.

Place
Date

Imran Ahmed

INDUSTRIAL TRAINING AT MENUFACTURING AND QUALITY

CONTROAL FOR CSD & NCB

CERTIFICATE OF ORIGINAL WORK

This is to certify that the industrial report entitled QUALITY
CONTROAL AND MANUFACTURING FOR CSD & NCB BEVERAGES is done
by Imran Ahmed student of B.Tech Biochemical Engineering 6th
semester under the supervision of D. K. Singh (A.M) , Mr. Praveen Shukla
and Executives Mr. Pravendra Singh (microbiologist).
To the best of my knowledge and belief the work has been complete by this
candidate himself.

Date:
Mr. Nitesh Jain
Place:
Manager- Quality
PepsiCo India
holdings Pvt. Ltd.
BA
ZPUR

Index
NO.

Topics

Page no.

Introduction about PepsiCo

1-2

Water treatment plant

2.1 Breif out line

3-4

2.2 BORE WELL

2.3 STORAGE TANK

5-16

Types of water
3.1 Raw water
3.2 Treated water
3.3 Soft water
3.4 Soft recovery water
Syrup preparation

RM/PM testings

19-25

Glass line

25-27

Conclusion

28

References

29

16-19

INTRODUCTION
Soft drinks constitute one of the largest beverage 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.
The beverages are divided into two groups i.e. carbonated soft drinks like Pepsi,
Mountain Dew, M. orange, 7 Up etc. & non-carbonated soft drink like Slice.
The major ingredients of soft drinks are
a) Water
b) Sugar or sugar substitute
c) Carbon dioxide
d) Flavor emulsion and emulsifiers
e) Coloring agents
f) Acids and preservatives

Origin Of Pepsi
In North Carolina, Mr. Caleb Bradham who was a pharmacist by profession invented a new
beverage in year 1898, which was called Brads Drinks (evocation of a digestion aiding enzyme
pepsin). This brads drink was later called PEPSI COLA. Pepsi Cola trademark was registered in
1903.Bradham believed marketing would be the key to Pepsi cola. He spent $ 1900 on advertising
when he sold only 40,000 liters of syrup.
In 1905, Bradham build Pepsis first bottling plant. Three (3) more plants followed soon and in
1907, he was selling 50,000 liters per year. In 1909, he hired a new advertising agency.
Troubles started at the end of the world war 1 st when Bradham overstocked sugar at high price
which subsequently dipped to rock bottom in 1920. by 1922, the company was insolvent and by
1923, it went bankrupt. Bradham returned to his pharmacy.
Roy Megargell, a wall street broker stepped in and reorganized the company. However the company
was running a loss each year and with the stock market crash in 1929. Megargell was not able to
upkeep the company any longer in 1930.

Indian Story of Pepsi

In 1977, a change in government at the center led to the exit of Coca Cola which preferred to
quite rather to dilute its equity to 40% in compliance with the Foreign Exchange Regulation Act
(FERA). The beginning of 1980s saw the birth of another Cola drink, Thums Up. The GOLD
SPOT people launched it in 1978-79, as Refreshing Cola in 1978, Parle led the Indian soft-drinks
market (share 33%) with its Gold Spot and Limca brands, in 1978, pure drinks share came down to
21% as a result of growing popularity of Limca and Thums-Up. At the same time the threat to the
Indian soft-drinks market was that of fruit drinks. In 1988 fruit drinks market was valued at Rs.
40Crores and grew at the rate of 20%. In early 1985, the government rejected a proposal with the
R.P.Goenka Group. This involved the export of fruit juice concentrates from Punjab in return for the
import of Cola-Concentrates. The deal offered was 3:1 export import ratio in return for being
allowed to market Pepsi in India. The Rs. 22Crores Pepsi Co project / package were the second bid

by the U.S. headquarters MNC to enter India. PepsiCo would have an equity holding of 39%,
Punjab Agro Industries Corporation (PAIC) 20% and Voltas 24%. The rest had to be financed
privately from loans. A project approval board was finally set in February 1988. Pepsis share which
have been originally just under 40% and PAIC 35% then PAICS share was hiked to 40% these
were mainly the issue in which COKE had left India in 1977. Thus Pepsi not only accepted the
1977 conditions but also went much further. Now the Pepsi project had captured the farmers
imaginations. Finally there was victory for Pepsi who after more than 5 years of acrimonious battle
was launched in June 1990 selectively in Rajasthan, Punjab, Uttar Prades and South as LAHERPEPSI.

Pepsi Bottling Plant, Bazpur

PepsiCo India Holding Pvt. Ltd (Bazpur) is a green COBO ( COMPANY OWNED
BOTTLING OPERATION) plant of pepsi cola international. It is located on Beria road, Bazpur
about 55 km. away from Nanital, Uttarakhand . The occupied area is absolutely population free. It
is one of the foremost manufactures of non alcoholic corbonated beverages. The annual production
of beverage is 10 million cases. The plant was opened in the year 1997 and bottling started from 5
May 1998.
The plant of PepsiCo India Holding Pvt Ltd. at Bazpur has an effective manpower of more
than 300 which includes both line and staff authorities. The achievements of the plant includes,
International Quality Award (IQA) for housekeeping, Qualifying AIB audits, Quality and Food
Safety Award, AMEA Region, PI.

The plant layout is divided into following areas:

1. Administrative Block
2. W.T.P
3. Utility Areas: D.G., Boiler, RAC
4. E.T.P.
5. Syrup Room

6. Manufacturing Area:
Line 1: PET 600 ml
Line 2: PET 600 ml, 1ltr, 2ltr,
2.25ltr
Line 3: PET 1ltr Aquafina
Line
4:
GRB
(Glass
Returnable Bottles) 200ml,
300 ml

1. RM/PM TESTINGS
RM PM is raw material & packaging material which is subsistently is a
inventory quality control method for assuring good quality measure in inventory
& packaging material
4.1. Tests Performed On Sugar

Test-1: Color Test

Purpose: The color test measure the amount of impurities in sugar which is a
primary indication of sugar quality.
Sources of color:
1. Plant materials
2. Refining process by produced
Procedure:
1. Dissolve sugar sample in water to 50 brix.
2. pH adjustment if necessary.
3. Filter sample through vacuum assembly (0.45 filters).
4. Degas sample.
5. Fill sample in cell.
- One of sample to be analyzed.
- One of distilled water for reference.
6. Place cells in spectrophotometer (420 mm ).
7. Determine reading by using approved calculation
Color IU =

Reading * 1000
(A cm cell length)* (B g/ml solid)

Where,
A, sample cell path length in cm
B, sample solids concentration in g/ml.
Test-2 Turbidity Test

Purpose: To determine amount of haze/cloudiness in sample caused by

contamination.
Equipment:
1. Spectrophotometer
2. Vacuum pump
3. Filtration unit
Procedure:
1. Dissolve sugar sample in water to 50 brix.
2. Deaerate sample
3. Fill sample cells
- One of sample to be analyzed.
- One of distilled water for reference.
4. Place cells in spectrophotometer and determine unfiltered reading at 420
m.
5. Filter sample through vaccum assembly (0.45 filters).
6. Fill sample cells
- One of sample to be analyzed.
- One of distilled water for reference.
7. Place cells in spectrophotometer and determine filtered reading(color).
8. Calculate turbidity

Turbidity =

(Reading before filtration reading after filtration) * 1000

(cm cell length) * (g/ml solid)

Test-3 Taste, Odor, and Appearance Test

Purpose: To ensure that no gross contamination in sugar exists.

Specification:
1. Taste of an acidified 10 brix solution should be sweet with no presence of
abnormal flavors.
2. No off odor should be present.
3. Sugar should be free of foreign material

Equipment:

Odorless plastic cups

Procedure:
1. Weight 10 gm of sugar.
2. Add 90 ml treated water.
3. Add 35 l phosphoric acid
4. Dissolve
5. Transfer into plastic cups with lids
6. Check appearance for color and foreign matter
7. Swirl and check odor.
8. Check taste.
Test-3: Ash Test
Purpose: Measure organic and inorganic salts due to the refining process.
Equipment/ Reagent:
1. Conductivity meter
2. Deionizer water
3. 0.01 N KCl
4. Balance
5. Water both
Procedure: ICUMSA (international commission uniform method sugar
analyses)
1. Measure conductivity of deionizer/ Distilled water.
2. Acquire and mix sample with deionizer water to 28 brix.
3. Adjustment temperature of sample to 20 0.5C.
4. Place conductivity cell in solution flush cell 2-3 times with solution.
5. Read results and calculate ash level
Sample conductivity - (0.35) * (water conductivity)
Ash% =
1666.7
Result and calculationAsh% = * corrected conductivity
Corrected conductivity = conductivity of sample - 0.35 * conductivity of water
Observation:
Sample conductivity = 23.5
Deionized water conductivity = 6.5
Calculation:

Corrected conductivity = 23.5 0.35 * 6.5

= 21.22

Ash%

= 21.22/1666.7
= 0.0127%

Test-4 Taste, Odor, and Appearance Test

Purpose: To ensure that no gross contamination in sugar exists.

Specification:
1. Taste of an acidified 10 brix solution should be sweet with no presence of
abnormal flavors.
2. No off odor should be present.
3. Sugar should be free of foreign material
Equipment:
Odorless plastic cups
Procedure:
1. Weight 10 gm of sugar.
2. Add 90 ml treated water.
3. Add 35 l phosphoric acid
4. Dissolve
5. Transfer into plastic cups with lids
6. Check appearance for color and foreign matter
7. Swirl and check odor.
8. Check taste.

Test-5 Beverage Floc

Purpose: The beverage floc test serves as an indicator of sugar which is likely to
from a floc in beverage. Beet sugars typically have a greater tendency to from floc
than cane sugar.
Equipment:
1. Balance capable of weighing to 1 g.

2. pH meter with electrode

3. Hot plate
4. 300 ml vessel stainless steel or Pyrex beaker
5. Stirrer electric rod immersion type or equivalent.
6. Watch glass to cover 500 ml vessel.
7. Pipette 10 ml.
Reagents:
1. Distilled water
2. ortho Phosphoric acid 85%
3. Buffer pH 2.5
Procedure:
1. Accurately weigh 250 g (1 g) of sample sugar into 500 ml beaker.
2. Weigh 250 g distilled water into the same vessel.
3. Stir unfilled completely dissolved.
4. Standardize the pH meter with the 2.5, 4.01, 7.00, 10.01pH.
5. Rinse the electrode with distilled water and place it into the sugar solution.
6. Using the 10 ml pipette, add phosphoric acid drop wise until the pH of
The sample solution is lowered to 2.0 0.1.
7. Place the sugar solution on the hot plate and heat just to boiling.
If a vessel is used that is not stainless steel, use a boiling water bath to
Heat the solution. As soon as if begins to boil, remove the vessel from
The hot plate and cover it with a watch glass.
8. Allow the solution to remain totally undisturbed for 48 hour.
After 48 hours, observe the solution carefully for traces of floc.
If floc is present, a Fail ranking is indicated and test may be stopped.
9. If no floc is noticed after 48 hours, make daily observation for the
Next 8 days. If floc for is present, a Fail ranking is indicated.
If no floc is evident after a total of 10 days, a Pass ranking may
Be assigned.

Test-6 Foreign Matter in Sugar

Purpose: To check sugar sample for presence of foreign matter.

Equipment:
1. Vaccum filtration apparatus capable of supporting 8.0 micron filter pads.
2. Vaccum filtration flask 1.5 2.0 liter capacity.

3.
4.
5.
6.
7.
8.
9.

Drying oven
Drying dishes ,2- aluminum to support filter dishes in oven
Hot plate
Analytical balance capable of weighing to 0.0001 g.
Balance capable of weighing to 1 g.
Stirrer - electric rod immersion type
Beaker 1 liter and 0.5 liter capacity.

Reagent/Chemical: Distilled water, prefiltered through 8.0 filter pads.

Procedure:
1. Weight 300g of distilled, prefiltered water into a 500 ml beaker, and heat just
to boiling.
2. Weight 300 g of sugar sample into the 1000 ml beaker.
3. Weight 500 g of distilled, prefiltered water into the same beaker as the sample.
4. Stir until the sugar is completely dissolved.
5. Assemble the filtration apparatus with two 8.0 fitters on top of each other in
the filter assembly.
6. Heat the sugar solution just to boiling.
7. With vaccum, filter the entire hot sample solution through the filters.
8. Rinse the sample beaker with the 300 g of hot water set aside in step -1 above
9. Filter this rinse water through the same filter as the sample.
10. Place the two filter pads in aluminum weighing dishes and dry in an oven at
90C for 5 minutes.
11. Remove the pads, equilibrate to room temperature, and weigh each pad to
0.0001 g.
Calculation:
First calculate the difference in wt between the two filter pads used in the
filtration .The Top filter pad should hold all the foreign matter and the Bottom
pad should serve as the Blank having no foreign matter on if
Wt of foreign matter gram = wt of Top filter pad wt of Bottom filter pad
Then, calculate the ppm of foreign matter in the sugar sample as follow

Foreign matter ppm = wt of foreign matter in gm * 1000,000

Wt of sugar sample used in gm
Test 7- Moisture-

According to BUs specification sugar which is used to produce CSD should

have the moisture range 0.02 to 0.04 %..
Test 8- Microbial TestingIn microbial testing of sugar we check the yeast & mold count present in 100ml
sugar solution. According to BUs specification yeast & mold count should not be
more than 15.
Flock TestAccording to BUs specification sugar used in CSD preparation should be pure. To
check the purity of sugar we use 50 degree Brix of solution. To maintain Ph(pawer
of H+) up to 2 with the help of adding Ortho Phosphoric Acid. & than it headed on
hot plate after that it stands for 10 days.

Test -4.2 CO2 Purity

Purpose: To check the gross purity of CO2 supply.

1. Zohm negel CO2 purity test apparatus
2. Regulator
Procedure:
1. Regulate CO2 flow to less than 10 psi.
2. Attach zahm negel apparatus.
3. Purge apparatus.
4. Collect sample.
5. Add caustic solution 10 %.
6. Bubble CO2 through caustic
7. Rotate apparatus
8. Read % CO2 purity above 99.0 %.

4.3 TESTING OF CHEMICALS

1. Ferrous Sulphate (FeSo4):Specification
1-Purity not less than 99.5%
2-Insoluble matter not more than 1%.
% (Purity)=T.R*2.78%.
2. Activated Carbon Granular:-specification

1-Moisture (max)-10%
3. Commercial Salt:-specification
1-Purity not less than 97.5% on a dry basis.
%(Purity)=TR*0.1*.05844*100/wt. of sample.
4. Caustic Soda Flakes:- specification
1-Purity not less than 96%.
%(purity)=TR*0.8*100/wt. of sample.
5. HCL:-specification
1-purity not less than 31.5%
6. Hydrated Lime:-specification
1-purity-Available CaO=66%(>90%as Ca(OH)2)
2-Inert material=none
%(purity CaO)=TR*1.87/wt. of sample
%(Ca(OH)2)=% of CaO*75/56
7. Bleaching powder:-specification
1-Available Cl2=>70% by weight.
%Cl2=TR*14.184/wt. of sample
8. Hyflow Super cell:-specification
1-Color-light pink to white
2-PH value-10(max)
3-moisture-0.5%(max)
9. Testing of Water(WTP)
Hardness
Softness
Alkalinity
Chlorine
10. Testing of flavour & Salt
Testing of flavour & salt are performed in Channo plant Punjab.
Flavour made up of two parts Concentrate
Acid part

 The formula of concentrate is secret.

The acid part contains citric acid anhydrous ,potassium sorbate, malic
acid, tartaric acid.

Packaging materials
1. Cartons Test-To measure Length, Width, Height, Printing, GSM.
2. Wrap around-To measure Length, Width, Center to Center, Printing, GSM.
3. Closures- To measure Weight, Height, SST, and Printing address, CDV, FPO,
CHL no.)
4. Crowns-To measure Weight, Go/No Go, Printing(address, CDV, CMD,
Nutritional information, Ingredients, CAT-1 & CAT-3), Corrosion Test, Liner
Adhesion,
5. Labels-To measure Coil Width, Repeat Length, Coil ID, Coil OD, Core
Thickness
Visually Check (plant address, nutritional information, ingredients, CAT-1 &
CAT-3), GSM
6. Sleeves- To measure Coil Width, Repeat Length, Coil ID, Coil OD, Core
Thickness
Visually Check (plant address, nutritional information, ingredients, CAT-1 &
CAT-3), GSM.
7. Empty Glass Bottles- To measure Weight, Height, Base Diameter, Shoulder
Diameter, Brimful Capacity, and Volume at fill point, Mould Number.
8. Preform tests TO measure Height, Weight, Neck finish, Internal neck
diameter, External neck diameter, Preform diameter, Gate height, Preform defects
in Polariscope

WATER TREATMENT TEST:1.ALKALINITY ( 2P-M ):-

PURPOSE:- The purpose of the 2P-M or alkalinity test is to verify that the
water treatment plant is operating correctly and that the final treated water used
for the processing conforms to standards. High alkalinity in process water will
have an undesirable effect on the taste of the finished beverage.

PRINCILAL OF OPERATION:-

The numerical value of 2P-M is

expressed as A (2P-M) and indicates whether the hydrated lime dosage, or

excess of hydroxide alkalinity, is correct. At the same time, the method measure
M the total alkalinity. The P alkalinity represents all of the hydroxide alkalinity,
and one half of the carbonate alkalinity. The alkalinity relationship is based on the
fact that the bicarbonate and hydroxide from cannot co-exit.
There are two approved method for measuring the alkalinity of the water. One
uses two colorimetric indicators, which change the color of the solution under test;
this is suitable for operation that does not have access to pH meter. The other
method is preferred since it removes the subjectivity of interpreting a color change
and uses a pH meter to determine the test result.

REASENT :

N/50 (0.02N) Sulfuric acid

P indicator (Phenolphthalein )
M indicator (Methyl purple)
T solution (Sodium thiosulfate)
Distilled water
Water sample
Add. Phenolphthalein indicator
Titrate 0.02 N H2SO4
Pink to colorless end point
Record ml 0.02 N H2SO4 P reading
Add. Methyl purple
Continue titration
Color change from green to purple
Record total 0.02N H2SO4 usage M reading

2.HARDNESS (CALCIUM & TOTAL):PURPOSE:- Water hardness is treated for at least two reasons :

In plant where sodium alkalinity is present, to monitor the effectiveness of

coagulation system by gauging the need for addition of a calcium salt to the
reaction tank,
Where water is softened to demonstrate the effectiveness of the softening
process.

PRINCIPAL OF OPERATION:-

Hardness in water is caused by

dissolved minerals, primary those producing divalent or double charged, cations
including
calcium
(Ca2+),Magnesium
(Mg2+),Iron
(Fe2+),Strontium(Sr2+),Zinc(Zn2+), & Manganese (Mn2+). Calcium &
Magnesium ions are usually the only one present in significant concentration in
most waters; therefore hardness is generally considered by our industry and by
the municipal water treatment industry to be a measure to be a measure of the
calcium and magnesium contact of water.

TYPE OF HARDNESS:Temporary or carbonate hardness:- It is the hardness due to the

bicarbonate of calcium and magnesium in the raw water. By classical definition,
this type of hardness can be removed by boiling the water.
In the soft drink industry, temporary hardness is removed by the cold lime
treatment that also reduces the alkalinity at the same time.
Ca(HCO3)2 + Ca (OH)2

2CaCO3 + 2H2O

Mg(HCO3)2 +2Ca(OH)2

2Ca Co3 +Mg(OH)2 + 2H2O

Carbonate or non- carbonate hardness:- It is the due to the chloride and

sulfate of the calcium and magnesium in the raw water. This hardness cannot
removed by the boiling the water.
This type of hardness is not removed by the cold lime process. To remove this
hardness with a conventional system, soda ash (Na2CO3)must be added to the
water. This then forms the calcium and magnesium carbonates, as the reaction
below illustrates, which precipitate in the reaction tank.
CaCL2+Na2CO3

CaCO3 + 2NaCL

EFFECT OF HARDNESS ON SOFT DRINK:-

Calcium hardness, when present in moderate amounts (Less than 70ppm.) does
not adversely affect traditional soft drinks. (For example. Pepsi, 7UP,
Orange.)There fore no special effort
Water used for sanitation purposes should be from a sanitary supply. If the water is
form a municipal supply with good quality characteristics and meets sanitary
criteria, it can be used for without further treatment for other
Sanitation programs.
If the plant water supply tests positive for coliform or contain any other
dangerous organism, this supply cannot be used in the sanitation process.
If the water is form an acceptable water supply and taste negative for coliform,
then simple chlorination is sufficient, maintaining approximately 0.2ppm free
available chlorine at the outlet.
In Pepsi Co. India Holdings Pvt. Ltd., Bazpur, the three types of
water used :

Raw water
Soft water
Treated water

We use raw water for storage purpose, drinking, canteen use etc.
Soft water used for cooling tower, bottle washer and boiler. Treated water used for
syrup and beverage making.
Raw water is pumped up by bore well & put to various treatment to obtain
Treated Raw water, having hardness due to Ca++ & Mg+ ions is softened with
the help of sodium zeolite. Which act as a softner. It absorb all hardness present in
the water it is the replaced periodically after use.
Soft water is mainly used for washing purpose. it is also used in boiler and
refrigeration empty bottles & equipment are washed using soft water.

Quality test for Carbonated soft Drinks (CSD)

Test.1 Gas Volume Testing

Objective: To check Gas volume (CO2) present in bottle.

Equipment:
1. Zahm nagel hand shake tester.
2. Terries make calibrated pressure gauge
3. Terries make calibrated dial thermometer

4. Pepsi CO2 scale.

Procedure:
1. Verify the calibration status of the pressure gauge and
Dial thermometer.
2. Sample selection and preparation
2.1 for line check select crowned bottle with fill height to 55-60 mm.
Equilibrate by gently inverting the bottle for 20 times in 30 seconds.
2.2. for trade sample, ware house sample and beverage shelf life sample.
Chill the product to 5+-10deg.C and equilibrate by gently inverting 10
times in 15 seconds.
3. After equilibrating, wait for the bubbles to clear the liquid.
4. Cover bottle with leather safety ground.
5. Place the sample bottle under the tester and align crown or closure with the
piercing device.
6. Close the snift valve at the front of the tester.
7. Grip lack spring and carefully lower the cross bar until the sealing ring or
piercing needle
rest on the crown.
8. Pierce the crown by forcing the cross bar down with a firm rapid motion.
9. Release the lock springs.
10. Push the thermometer into the bottle before it touches the beverage.
11. Release head pressure by carefully opening the sniff valve.
12. Close the valve as the head pressure reaches 2 psi.
13. Push the thermometer into the bottle as for it can go.
14. Hold the bottom and the tester pad in one hand and the cross bar in the
other. Shake the tester vigorously in a horizontal motion until the pressure
gauge reads a constant maximum pressure.
15. Record the constant pressure and temperature.
16. Convert pressure and temperature togas volume using Pepsi CO2 wheel.
17. Before removing the bottle from the tester, open the snift valve and vent
until pressure reaches zero.
Note: It is preferable to use gv shaker to bring more accuracy and uniformity
in testing.

Test.2 Brix of CSD

Brix: It is the amount sucrose present in solution. 1 brix means 1 gram of sugar
in 100 grams of water. It is measured by refractometer.
Objective: To check the amount of sucrose present in the product.
Equipment1. 250 ml glass cylinder
2. Refractometer
3. 300 ml stainless steel breaker
4. Dropper
5. Tissue paper
Procedure:
1. Sample preparation
1.1 For sample syrup, finished syrup and control drink take sample directly.
1.2 For carbonated beverage degas the sample.
2. Clean refractometer prism with distilled water and wipe it dry with tissue
paper.
3. Using a cleaned and dried eye dropper place a drop of distilled water on the
prism surface so as to cover it fully, close prism cover and press READ
key.
4. If reading is showing 0.00+-0.01 then proceed with the measurement.
1. Wipe the water from the prism dry and place a drop of the testing sample,
so as to cover the prism avoid gas bubbles by degassing the sample prior
to testing if required.
6. Close the prism cover and press READ key.
7. Once the display stabilizes on the screen it is desirable to take another
confirmatory reading by pressing the READ key again.
8. Record result.
Factors that have direct effect on brix are:

Accurate calibration of finished syrup tank (once a year)

Accurate measurement of simple syrup volume.

Accurate measurement of simple syrup brix.

Calculation of sugar content (to be maintained as per beverage document).

Concentrate addition under supervision of chemist.

Accurate measurement of finished syrup brix and volume.

Calibration of hydrometer for syrup brix every week.

Control drink brix/ inverted brix/ TA to be checked to ensure quality of syrup

Note: Beverage brix at times found out of target at start up, during batch change
over and at the end.
Reasons:
1. Sop not established/ standardized or not being followed rigidly.
2. Lack of knowledge of chemist/ operator to operate mix processor.
3. Syrup line not flushed properly before taking syrup leading to dilution of syrup
in the initial stage.
4. Co2 pushing is not used to flush water.
5. Mix processor and filler are not flushed with sufficient beverage (10 psi co2
pressure to be used for flushing).
6. Air entrapment in the syrup during batch change and end production leading to
low brix.
7. Water being used in some plants to push syrup instead of co2.
8. Mishandling of refractometer.

Test3. Inverted brix

It is the measure of sugar inversion i.e. Inversion of sucrose into glucose and
fructose.

Degas the beverage as per the degassing study.

Clean & rinse the bottle properly.

Take 35 ml of the degassed sample in the bottle.

Add 0.4 ml of 2.5 N HCl in the sample.

Seal the bottle properly and mix the beverage.

Keep the bottle in boiling water for 40 minutes.(time starts only when the
water starts boiling).

Cool it to 20 c.

Check brix as per sop.

Add correction factor based on the flavor as per the beverage document.

Test 4. Control drink

Aim: A control drink is an individual drink made by hand. A control drink may be
made with treated water to find out what the line beverage target for titratable
acidity or brix should be and if the taste of the finished beverage is acceptable.
Reagent/ Chemical: syrup and treated water
Process Flow Diagram:
Acquire well mixed syrup sample
Mix syrup and treated water in 1:5
ration in a CD flask; for mirinda
make the ratio 1:4

Mix thoroughly using magnetic

stirrer
Test for pH, TA and final brix

Fig 10: flow diagram for CD making

Important things related to Control Drink:

Control drink to be made two hours prior to production and then every 4
hours.

Line target to be based on inverted brix.

Syrup brix must also be checked while making control drink. It gives an idea
about the accuracy of control drink.

Dont forget to add 0.4 ml of 2.5 N HCl in flavors except Pepsi for every 35
ml of beverage before inverting.

T.A. (Titrable acidity)

It determines the acidity level of beverage. It is performed by titrating 100 ml of
degassed beverage against 0.1N NaOh till ph 8.75.
Factors effecting T.A are:

Calibration of finished syrup tank (once a year).

Sugar content in simple syrup.

Spillage of concentrate during transfer due to mishandling and leakage in the

line.

Manual mixing of salts in buckets leading to splashing.

Leaking buckets.

Recirculation line not provided for mixing of salts.

Hydrometer not calibrated.

Finished syrup brix not maintained.

High alkalinity of treated water.

Ta reduced by 1 ml if alkalinity is 50 ppm. Preferably alkalinity to be

maintained between 20 - 25 ppm

Caustic carryover reduces TA by neutralizing acid.

Brix variation.

Too much foam on the conveyor: possibility of foam entering in the bottle
which neutralizes the acid.

Degassing study not done properly.

False alarm on TA due to improper degassing of beverage/ normality.

0.1 N NaOH solution not standardized (range : 0.1 +/- 0.002)

Manual ph meter used where the calibration is not guaranteed.

Temperature compensated automatic ph meter to be used.

pH meter to be calibrated daily with standard buffer solution and slope to be

calculated.(slope should be between 95 - 105 %).

Buffer solution to be kept in fridge at 4 c and discarded after 7 days.

False reading of TA due to increase in calcium hardness.(this can be overcome

by 10% tri-potassium citrate in Pepsi only).

Test-1 Total Dissolve Solids

Purpose: The purpose of this test is to provide a rapid, indirect approximation of
the TDS in a water sample as measured by its electrical conductance.
Equipment: Conductivity meter, Glass container, Thermometer
Reagent/Chemical: Distilled water
Procedure:
1. Pour approximately 50 ml of distilled water into the glass container and insert
the conductivity cell probe.
2. Move the probe up and down several times to wash off any solid, present in
the cell.
3. Discard the water in container.
4. Measure to temperature of the sample and adjust the temperature correction
deal on the conductivity meter.
5. Insert the conductivity probe and move it up and down several times to
ensures equilibrium and to displace any large air bubbles trapped at the top of
the cell.
6. Measure either the total dissolved solid directly in mg/lit or ppm.
Formula:
TDS mg/lit. = conductivity (micro siemens) * 0.67(conversion factor)

Test-2 pH Test
Purpose: This method will provide an overview of pH measurement of water.
Equipment: pH meter, thermometer, 250 ml beaker, tissue paper.
Reagent/Chemical: Distilled water (for rinsing electrode)
Procedure:
1. Use a conditioned pH electrode and a calibrated pH meter.
2. Turn on pH meter.
3. Rinse the electrode thoroughly with distilled water and dab dry with disposable
tissues.
4. Pour the water to be analyzed into a clean beaker.
5. Carefully place in clean, dry stir bar into beaker containing water.
6. Allow pH to stabilize and record pH to the nearest 0.1 pH unit.
7. Rinse electrode with distilled water.
Line-4 Glass line
This line produces 200ml and 300ml of reusable glass bottles. This is a very
important segment of plant. It is also very important from quality point of view as
it is very prone to microbial growth.
Main component of glass line is: Bottle washer, filler, Coding machine and case
packer.
6.3.1

Bottle washer system

Importance of bottle washer

Shelf life of finished product will invariably be reduced inspite of using

best quality water, sugar, concentrate etc. If the bottles are not properly
cleaned and sanitized.
Improper washing of bottles will adversely affect the sensory of the
product due to micro contamination and mold growth.
Bottle washing process looks very easy. Hence we neglect it.
However, it is the most important area where we have to give our
maximum efforts.
Normally concerned persons feel that bottles feeded in bottle washer will
automatically get cleaned without caring for the operation of the bottle
washer.

Before bottle washer, remove the followings

1. Very dirty/contaminated/mold infested empty bottle (group 3 bottles).
2. Full crates if dirty empties are high in numbers (around 8-9 bottles).
3. Straw/ rusty neck.

4. Mix brand bottles.

5. Other brand crates.
6. Chip neck bottles.
7. Bottles having pouches, insects etc.
8. Whole pallet to be rejected if excessive dirty bottles are visible
Single line inspection is the most effective answer.
The components of bottle washer are:
a) Pre rinse segment:

It is the most important stage of washing which is neglected.

It remove loose dirt and other foreign matter.

It avoids carryover of dirt into caustic tanks.

Jet pressure: min 2 kg/cm2

b) First soak :
To loosen & remove sticky material, dirt.
To pre heat the bottles.
Parameters
Caustic strenght: 1.5-2.0 %
Temperature: 50-55 c
c) Pre wash

To remove dirt & sticky material, this is loosened in pre soak.

Jet pressure: min 2 kg/cm2

Parameters
Caustic strength: 1.5-2.0 %
Temperature: 55-60 c
d) Main soak :
Purpose: To clean and sanitize the bottles
Parameters
Caustic strength: 2.5-3 %
Temperature: 72-77 c
Su 260 p: 800-1000 ppm
Soak time : 7.5 minutes
Carbonates: < 1 %
Note: Thermostat should be provided to control the temperature within the
recommended range.
Caustic:

Advantage
Caustic has germicidal action.
Caustic is a good cleaning agent.
Disadvantages
Caustic alone is not effective.
It cannot penetrate
It enhances scale formation due to formation of carbonates.
It attacks the bottle surface.
Additive (su)
It enhances the cleaning affect.
It softness mold pads & dirt in the bottles.
It increases rinsibility of caustic solution.
It prevents scale formation.
Helps to settle particulate matters.
Hence caustic soda with su-260 (as recommended by pfl) to be used.
Hydro spray:
To remove caustic residue.
To remove dissolved/ suspended dirt from bottles
To reduce temperature gradually to avoid thermal shock
e) Pre final rinse :
To remove left over caustic residue.
To further reduce temperature of the bottles.
Removal of caustic trance and cooling of bottle ( 1 to 2 ppm cl2).
f) Final rinse :
Bottles washed with soft water with 1.0 ppm free chlorine.
Water should be free from any particles.
Removes caustic residue fully.

g) Out feed : It receive bottle from carrier and guides to the conveyor.
Flow diagram of bottle washer system
Bottle feed

Pre Rinse
First Soak

Caustic 1.5 %
At 55 deg C

Caustic 2.5

Main Soak

At 70 deg C

Soft water

Hydro Spray

Caustic < 1.5 %

Pre Final Rinse

Final Rinse

Bottle Out

Fig 13: Flow diagram for bottle washer system.

6.3.2 Test In Glass Line

Test-1 Caustic Strength
Aim: To heck the concentration of caustic in solution of pre and main soak.
Equipment:
1. 10 ml Burette
2. 10 ml pipette
3. 10 ml measuring cylinder
4. 150 ml conical flask
5. 50 ml Graduated cylinder
Reagents/Chemical:
1. 2.5 N sulfuric acid
2. 10 % Barium chloride solution
3. Phenopthalein indicator solution
4. Distilled Water
Procedure:
1. Open the sample cock of bottle washers and discard the first 150 ml and 200 ml
of caustic solution.
2. Collect the caustic sample from bottle washer soak-1 and bottle Washer soak-2
separately in a clean and dry glass bottle.
3. Pipette out 10 ml of caustic solution and it into 100 ml conical flask containing
10 ml of distilled water.
4. To this solution and 5 ml of 10% barium chloride solution and mix thoroughly.
5. Titrate the solution against 2.5 N sulfuric acid solutions by using
phenolphthalein indicator, till the pink color disappears.
6. Note the titrate value.
7. Calculate caustic strength .
Caustic Strength = Titre Value * Strength of Sulfuric acid * 0.04 * 100
Volume of sample Taken
Where 0.04 = milli equivalent of Sodium hydroxide

Test-2 Methylene Blue

Aim: Methylene blue test is performed to check presence of molds in bottles.
Equipment:
1. Eye Dropper
2. Funnel
3. Weighing Balance
4. 1000 ml Volumetric Flask
Reagents/ Chemical:
1. Methylene Blue Powder
2. Distilled Water
3. 95% Ethanol solution
4. Treated Water
Procedure1. Methylene Blue Stain Preparation (0.1%)
1.1 Varity the calibration status of weighing balance.
1.2 Weigh 1gm of methylene blue powder.
1.3 Dissolve in 50 ml 95% ethanol solution.
1.4. Add 50 ml distilled water and stir to dissolve.
1.5. Dilute to 1000 ml with distilled water.
2. Stop bottle washer.
3. Collect all 55 bottles from 1dump/stroke of bottle washer at discharge.
4. Pour methylene blue stain (0.1%) into bottle using funnel. Fill up to 1/3rd
level.
5. Rotate the bottle to spread stain over the entire inside surface.
6. Wait for five minutes.
7. Rinse the bottle with treated water at ambient temperature 20 25deg C.
8. Discard rinse water and examine inside bottle surface mould will retain a
blue color.
9. Record Result.

Test-3 Carbonate Test

Aim: Carbonate test is done to check hardness of water.
Equipment:
1. 10 ml automatic burette
2. 10 ml pipette
3. 100 ml conical flask
Reagent/Chemical:
1. Standardized 2.5 N sulfuric acid
2. 10% Barium chloride
3. Phenolphthalein indicator
4. Methyl orange indicator
5. Distilled water
Procedure:
1. Open the sample cock of the bottle water and discord the first 150 ml and
200 ml of caustic solution.
2. Collect the caustic sample from bottle soak-2, separately in a clean and dry
glass bottle.
3. Pipette out 10 ml of this caustic solution and transfer into 100 ml conical
flask.
4. To this solution and 5 ml of 10% barium chloride solution and mix it
thoroughly.
5. Titrate the solution against 2.5 n sulfuric acid solution using
phenolphthalein indicator, till the pink color disappears.
6. Note titrate value.
7. Calculate P value.
P value = titrate value
8. Add 2 drops of methyl orange indicator to the above solution
And continue titration till the color change from yellow to pink.
9. Note titrate value and calculate M value.
M value = titrate value
10. From P and M value can calculated 2(M-P) percent as
Carbonate level.
11. Record result.

Test-4 Free SU Test

Aim: To find amount of free SU in solution.
Equipment:
1. 1 ml graduated pipette
2. 10 ml pipette
3. 100 ml conical flask
4. 10 ml burette
Reagent/Chemical:
1. Total hardness indicator
2. 2.5 N sulfuric acid
3. Ammonia buffer
4. SU reagent
Procedure1. Take caustic sample from soak-2 of bottle washer.
2. Measure 25 ml of the above sample and dilute it with 75 ml of distilled
water and determine its strength using 2.5 N sulfuric acid, record the
amount of titrant consumed.
3. Pipette out another 25 ml of the sample and 75 ml distilled water.
4. Add the exact amount of 2.5 N sulfuric acid as determined from steep-2.
5. Add 3 drops of ammonia buffer solution.
6. Add pinch of total hardness indicator and swirl gently.
7. Appearance of wine red or violet color indicates absence of free SU 260.
8. Appearance of blue color indicates presence of free SU260.
9. In case of presence of free SU 260, titrate the sample with
SU reagent till the appearance of violet or red color.
10. Record the quantity of SU reagent consumed say X ml.
11. Calculation
ppm of free SU 260 = X ml * 3470

Test-5 Divo LE-Chemical Test

AIM: To check amount of free LE in washing solution.
Equipment:
1. 1 ml Graduated pipette
2. 10 ml pipette
3. 100 ml conical flask
4. 10 ml Burette
Reagent/Chemical:
1. Erochrome black T indicator
2. Ammonia buffer
3. Divo reagent
4. Total hardness indicator
Procedure:
1. Draw water sample coming from pre final jet of bottle washer.
2. Measure 100 ml the above sample.
3. Add 3 drops of ammonia buffer solution.
4. Add one pallets of total hardness indicator and swirl gently.
5. Appearance of blue color indicates presence of free Divo le.
6. In case of presence of free Divo le; titrate the sample with
Divo le reagent, till the appearance of violet or red color.
7. Record the quantity of Divo le reagent consumed say X ml.
8. Calculation
ppm of free Divo Le = X ml * 95

Test-6 Crown Crimping

AIM: To check crowning of bottles.
Equipment: Calibrated Go-No Go crimping gauge.
Procedure:
1. Collect filled bottle from each crowner need.
2. Place the bottle on a level surface.
3. Use Go aperture 1.135 inch on each bottle
Crown-it should pass without hindrance.
4. Use No GO aperture 1.125 inch on each bottle
Crown-it should not pass.
5. Record result.

Test-7 Bottle Washing Caustic Carry Over

Presence of Caustic in bottle can:
1. Cause and off taste in the product
2. Affect the crown or closure.
3. Course the bottle to look dull instead of clean and clear.
Purpose: To confirm the absence of caustic in container that have been washed
and rinsed. A bottle out transfer tank with caustic carryover is not considered
clean.
Equipment: Eye dropper or squirt bottle.
Reagent/Chemical: Phenolphthalein indicator
Procedure:
1. Add 3-4 drops of Phenolphthalein indicator to neck of bottle.
Rotate bottle for even distribution of indicator.
2. Add 5-6 drops of Phenolphthalein indicator to lip of bottle and outside neck
area, rotating bottle for even distribution.
3. Any red/pink color indicates caustic carryover.
4. Record and report out come and action.

Test-8 Fill Height

Aim: To measure fill height.
Equipment: Calibrated fill height gauge
Procedure:
1. Collect to crowned bottle corresponding to filling valves of the filler from
the production line.
2. Set he bottle on a level surface rest the top bar of the gauge on the crown in
a level position.
3. Slide the pointer until the top of the caliber coincides with the lower
meniscus of the liquid level.
4. Read the mark on the scale.
5. Record result.

Test-11 Net Contents

Aim: The bottle has a legal and ethical obligation to provide the consumer with
the amount of product declared on the package.
Equipment1. Electronic balance with 3000 grams capacity and 0.1 gm accuracy.
2. Drainage rack
Procedure1. Acquire a filled and sealed bottle.
2. Ensure the outside is dry and clean.
3. Weight the full bottle and record the weight.
4. Completely drain the bottle in drainage rack, about 30 seconds.
5. Record the weight of the empty bottle. Include pull tab from crown.
6. Calculate the net content weight in grams from the following equation.
Net content (gm) = wt full bottle (wt empty bottle+ crown)

Test-13 Candling For Foregn Material

Aim: This method is intended to identity foreign materials in bottle beverages via
candling observation with follow up confirmation of suspected positive by
filtration.
Equipment:
1. 300 watt projection lamp with a 30-40 mm lens.
2. Ring stand or other holder for inverting bottle.
3. Millipore filtration system with 5 filter proper for large particulates 0.45
filtration for small particulates.
4. Binocular microscope
Procedure1. Hold bottle in front of light soure and gently agitate. If floc or any other
foreign substance is observed, mark the container and set it aside for
confirmatory filtration or further testing.
2. Invert the bottle and immediately place if in the holder approximately one
inch from the light source, slightly off center.
3. Observe the neck area above the closure or crown for at least 30 seconds
watching for foreign material entering these areas.
Scan the remainder of the container for suspended or floating materials
- Glass falls directly, reflects and refracts light
- Fiber floats and is translucent to light
- CO2 bubble vary in size, floats, drifts up and down, transparent to light
- Plastic, organic growth and cellulose will float, suspend, or fall
4. Mark and set aside those containers with presumptive foreign material
finding.
5. Filter all suspect products remaining after necessary analytical sample have
been removed.
6. Microscopically observe filter pads and identify any confirmed foreign
materials.

EQUIPMENT USED IN WATER TREATMENT PLANT

1. Poffer N.Norman; Food Science, III ed. (1987), CBS Publishers and
Distributers,
Delhi.
2. Colwell R.R. and Grigorova R.; methods in Microbiology, Vol. 19, (1987),
Academic Press INC. Florida.
3. Varnam H.A. and Evans G.N.; Food Borne Pathogens, (1991), Wolfe
Publishing Ltd. England.
4. Nielsen S. Suzanne; Introduction to Chemical Analysis of Foods, (1994),
Jones an
Bartlett Publisher, Boston, London.
5. Miller M. James and Crowther B. Jonathan; Analytical Chemistry in
G.M.P.
Environment (2000), John Wiley and Sons, U.S.A.