Report on in-plant training

At YETI BEVERAGES PVT LTD.

URMILA KHULAL
10/10/2012

This document describes about the internship activities performed at the beverage company along with the short description of the factory, plant location and overall processing to manufacture pure processed bottled drinking water.

copyright reserved by the author of the report

2. Objectives:
1. To know the overall processing of the natural mineral water to the sterilized pure drinking water. 2. To understand the fundamental parameters and procedures of quality control and quality assurance of thus processed drinking water. 3. To get the basic idea of the managerial structure and parameters of an industry/factory for its successful running.

3. Brief Executive Summary of the Internship:

Yeti Beverage Private Limited, the factory where the internship was performed, is located in Nasikasthan, Bhainsepati, Banepa. This is the processed bottled drinking water manufacturing plant of the nation which is (International organization of standards) ISO 9001:2008 certified and thus very popular among the consumers in a very short period of time.

Since the water is one of the greatest and inevitable basic requirements of the living beings, humans want their drinking water to be completely hazardless and safe to drink. Knowing the fact, the factory is especially conscious and well aware of the plant sanitation and general hygiene either related to the workplace or with that of the workers personal hygiene. Good Manufacturing practices (GMP) is well practiced to avoid all possible product hazards.

Having in the mind to experience such environment to work in as well as to learn, this factory was chosen for an internship for which the great co-operation was shown by the staffs. I was supervised well enough by the production in-charge, in one department at a time and various queries and questions were properly answered. Since the production was carried out in the factory using the automatic machineries (as discussed under further headings), not much manual work and supervision was required thats why temperature, speed, pressure etc were set initially then supervised periodically. However, sometimes the production was carried out semiautomatically i.e. along with the laborers help in each section.

Theoretical knowledge was compared to that of the practical knowledge gained during the internship/in-plant training which made me confident on acquiring more of the practical knowledge so as to learn more and clearer. So, it would not be wrong to summarize the whole in plant training as one of the fruitful practical learning experience during the Bachelors program of food science and technology.

4. Table of contents:
1.WEEKLY SCHEDULE1 2.OBJECTIVES: ................................................................................................................................................. .2 3. BRIEF EXECUTIVE SUMMARY OF THE INTERNSHIP: ......................................................................... 3 4.TABLE OF CONTENTS: ................................................................................................................................. 4 5. INTRODUCTION OF THE COMPANY: ....................................................................................................... 6 5.1. ORGANIZATIONAL CHART OF YETI BEVERAGES PVT LTD: ...................................................................8 5.2. RAW MATERIALS REQUIRED FOR THE FACTORY: ....................................................................................9 5.3. MACHINERIES AND EQUIPMENTS: ..............................................................................................................10 5.4.FEW TERMINOLOGIES ..14 5.5. MANUFACTURING SYSTEM14 5.6. FLOW CHART OF MANUFACTURING PROCESSED BOTTLED WATER.15 5.7. PROCESSING DEPARTMENTS IN YETI BEVERAGES PVT LTD: ..............................................................17 5.8.MARKETING CHAIN OF THE COMPANY 17 6. INTERNSHIP ACTIVITIES: .................................................................................................................... 22

6.1.DEMONSTRATION AND INTRODUCTION TO THE MACHINE: .................................................................22 6.2.RAW MATERIALS QUALITY CONTROL AS WELL AS RESPONSIBILITY: ..............................................22 6.3.IN PROCESS QUALITY CONTROL (IPQC) 21 6.4.FINISHED PRODUCT CONTROL...................21 7. ASSESSMENT OF THE INTERNSHIP: ...................................................................................................... 25 8. PLANT SANITATION ...23 9. WASTE AND BY-PRODUCT...............................................23 10. R&D23 11.CONCLUSION AND RECOMMENDATIONS: .......................................................................................... 27 12.APPENDICES: .............................................................................................................................................. 28

Table of figures: Figure 1:organizational chart of the yeti beverages pvt ltd ..................................... 9 Figure 2:flow chart showing the manufacture of pure processed bottled drinking water .................................................................................................................... 16 Figure 3:showing semi-automatic bottle washing machine .................................. 17 Figure 4:showing bottle capping section and filling section respectively ............. 18 Figure 5:showing the label shrink packager ......................................................... 18 Figure 6:showing the preforms and the blow moulding machine ......................... 19 Figure 7:showing the jar filling and sealing section ............................................. 20 Figure 8:showing the market chain of the factory ................................................ 21 Figure 9:showing the production chart for the water processing .......................... 28 Figure 10:showing carbon filters and storage tank ............................................... 29 Figure 11:showing reverse osmosis RO machine and ozone generator................. 30 Figure 12:showing micron membrane filter and UV sterilizer.............................. 31 Figure 13:showing the ISO certification of the YETI BEVERAGES ................... 31

5. Introduction of the company:

Yeti beverages Pvt Ltd, is the factory manufacturing the processed, pure drinking water located in Nasikasthan, Bhainsepati, Banepa covering 10 ropanis of area just linked to the Araniko highway. The company is under the sole ownership and was solely established in 2007 A.D. However, the same company owns the nations highly demanded pipe and plastics of various sizes and types named under the Yeti plastics Pvt Ltd with the long history behind. The factory started to manufacture bottled yeti pure and processed drinking water since 2007 A.D. i.e. 2064 B.S. after the neighbor Bisleri drinking water manufacturing company was shut down. Since then the market has been just expanding. The company has been the member of Nepal Bottle Water Industries Associations (NBWIA).

Today, the factory produces i)yeti drinking water ii) Fresh n cool drinking water Similarly, factory also produces i) various gauges of plastic pipes According to the sana tatha gharelu udhyog praman patra, the company has registered to produce 1 million liters of pure and processed drinking water each year in the beginning. Now the production has increased by 3 times till the end of 2068 B.S. Of these products above, about 80% is consumed by the local market of Kavre district from the urban to the very rural areas of which the market chain and consumer has been shown below. Remaining 20% is consumed by the market of capital city and the some of the neighboring places of Bhaktapur district. In case of the plastic pipes of various gauge /gsm, it is circulated throughout the nation.

Among these two main bottled water production, 25% of the total production volume is contributed by Fresh n Cool whereas the remaining big 75% is contributed by the Yeti drinking water. The production on the daily basis is variable, mainly depending upon the market demand and slightly on the remaining stock. Roughly, during a production cycle in the semi automatic machines, the production is about 6000 liters-7500 ltrs i.e. within one cycle of about 3 hours. At the same time, the filling and sealing of the jars (20 liters) take place in the automatic machine in a higher speed thus producing about 150 jars per an hour. Similarly, the 500 liters tanker is also filled with the pure filtered drinking water whenever demanded.
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Some important information regarding the company: The factory has been registered under the Company Act 2063 dated 2064/01/24, time at 2 pm, certified by the ministry of commerce, industry and supplies, Nepal. It has been certified under the food technology and Quality control, Nepal too. Thirdly, the company has certainly been classified as the production company according to the article 3, a (dapha 3 ka) as well as the small scale industry according to the article 5.

The company is ISO 9001:2008 certified under sole ownership, initially established by Mr. Bivek kumar shah. The total asset of factory is Rs.10 million and its operational cost is Rs. 6 million. Total power permitted to use is 25 kW and according to the rules if the rate of production exceeds 25 ltr/sec then the company would have to be permitted IEE as well. The companys well conscious about following the consumers act 2054 and regulations 2056 thats why, is strictly conscious about their health and thus uses PET preform to produce its own bottles. The factory enrolls direct labors, emphasizes women laborers and just right in numbers, neither more nor the less than required so as to keep the production area less populated, organized and systematic. The target annual production is 1 million liters of water, pure, processed, and ozonized and UV sterilized. The annual production capacity however is 4.54 million liters. The company owns plastic manufacturing plants, and water processing as well as the pretreatment plants side by side. The company owns various machineries which will be discussed below in details. The plant layout is very satisfactory as is facilitated well to the workers with the canteens and sanitary rest rooms just properly located. Security is tight and no entry is possible without proper formalities. Security fence is very good and the workers are preferred from the locality so that they could get to the work in lesser time, for those away from their home towns, under some circumstances well facilitated quarters are provided along with the vehicles as per the nature of their jobs. The transportation facility is good with the ample amount of the vehicles. The factory is environment friendly so it takes care about not polluting the village, water, forest and the society around at the topmost level.
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5.1. Organizational chart of Yeti Beverages Pvt Ltd:

Director

CEO

GM

FM

Accounts

Sales/Purchase

Personnel

Engineering

Production

Quality

Store

Figure 1:organizational chart of the yeti beverages pvt ltd 5.2. Raw materials required for the factory:
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S.n 1.

Raw materials Raw water

Manufacturer Shallow and

Description of manufacturer deep Just near the factory and sometimes from the nearby village.

wells.(3)+reservoir

2.

Preform(PET)

TSN corporation Nepal

Multinational company importing, exporting, and manufacturing PET and polymers related materials.

3.

Jar + jar cap+ bottle TSN cap Nepal.

corporation For info: http://tsncorporation.com/manufacturing.html

The print is situated in Banepa and is popular 4. Label+ neck seal+ Chandeshwori cartons print. flex in Kavre district for the print solution, flex prints, cartons, labels etc.

5.

CaCO3, NaHCO3

Table 1: showing the raw materials and their manufacturer

5.3. Machineries and equipments:

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S.n 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 12 13. 14. 15. 16. 17. 18. 19. 20. 21. 22 23. 24. 25.

Machineries and equipment PVC tanks Pump Storage tank Salt containing jar Filters Salt containing vessel Membrane filter RO machine Prefilter Reserve tank HF4 ozone generator Filter UVC water sterilizer Pump Semi-automatic bottle washing machine Bottle filling machine Bottle capping machine Bottle labeling and neck sealing Shrink wrap machine Case packaging machine Cargo Blow moulding machine Jar filling machine Jar sealing machine Label stamping equipment 5 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3

Number

Capacity 2000 liter 5 hp 1500 liter 40 liter

20 liter 2X micron 1000 l/min 2X micron 2000 liter

7.5 hp 1000 bottles/min 1000 bpm 1000 bpm

50 cases 100 bpm 20 jars/min 20 jars/min

Table 2: showing the machines and equipments with their capacity

Generator
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Manufacturers name : Kohler Company Number Oil Oil consumption Total amp Volt Rpm : 4 : Diesel : 3.2 units/ltr : 2200 amp : 400 V : 1500

5.4. Few terminologies:

1. BPR (Batch Production Record) It is the systematic process of keeping the records as per GMP norms so that the errors can be eliminated. BPR provides instructions and procedures for in-process check, packing line check and finished product check. It is filled and checked by the both production chemist and QA chemist and finally gets audited by head of QA before dispatch.

2. BOM (Bill of Materials) It gives the amount of all the ingredients required for the production of a certain product. It actually gives the composition of the batch or lot to be produced.

3. MIN (Material Issue Note) It is the list of RM and PM required for the production of certain batch. It is sent with BPR by QA department to the store and it is forwarded to the production department before the production of the batch along with the issue materials.

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4. MRN (Material Return Note) After the production if the extra material is left then it is given back to the store with MRN.

5. MAN (Material Arrival Note) It is the system of recording all the purchased materials.

5.5. MANUFACTURING SYSTEM:

1. Firstly raw materials and packaging materials arrive at the factory with MAN. 2. After being approved by Q.A. these are sent to the store. 3. For the production, the production department asks for the raw material from the store. It sends MIN to the store and the amount of raw material required for the production according to BOM is issued by the store. 4. At the start of the production, the CIP process is carried out. 5. The production department prepares a batch according to BPR. 6. After being approved by the QA chemist the batch is sent for the processing. 7. Analysis of the finished product is then done. 8. The finished product is now undergone microbiological test. The finished products are dispatched from the warehouse only when the QA chemist assures microbiological safety. 9. All the lab results are recorded in the ISO report so that could be checked upon by the authority.

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5.6. Flow chart of manufacturing processed bottled water:

Figurative chart followed by the company has been shown in appendix 1. Flow chart for the manufacture has been shown as below:

shallow+deep well water

pump to the roof

water pretreatment
aeration chemical treatment(opt)

pump pretreated water

sand filter

storage tank

storage tank

Calcium carbonate (250 gm/40 litre)in case of CIP.

Tanker filling 4 filters 2 sand filters 1 carbon filter 1 ion-exchange resin

Sodium bicarbonate(200 gm/20 ltr) in case of CIP

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Reverse osmosis(RO) Shows TDS, input and output

Membrane filter

Filter i.e. prefilter

Reserve tank(2000 capacity)

litre

Ozonisation generator)
Filter

(HF4

ozone

PET preforms

rator) Filter

Blowing and moulding of bottles(Blow and mould machine)

UVC sterilization(water sterilizer) pumping

Packed in sacks Damaged sorted out. were Bottles were introduced through conveyor

Bottle washing machine Semi-automatic washing bottle

Bottle filling (bottle filler machine)

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Adjust the rate.

Bottle caps in hot water Labels stamped date and batch number. neck seals, cartons at the place of manufacture.

Bottle capping automatic)

(semi-

Labeling (manually)

Neck sealing Cartons

Shrink wrapping(shrink wrap machine) Adjust the temperature

Packing in cases Count and record product.

the

Stacking

Storage in a suitable room Figure 2: flow chart showing the manufacture of pure processed bottled drinking water
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5.7. Processing departments in Yeti Beverages Pvt Ltd:

Yeti Beverages Pvt Ltd manufactures and sells pure and processed bottled drinking water and the processing plant includes following various departments:

i) Bottle washing department: This is the plant in which the manufactured PET( polyethylene terephthallate) bottles are lined up in the conveyer so as to wash the bottles prior to the filling. The speed adjustment is done and monitored manually.(machine information is as mentioned above).

Figure 3:showing semi-automatic bottle washing machine

ii) Bottle filling department: After the proper washing of the bottles, these are filled in the filling department, generally 1 liter processed water is filled at the adjusted rate under strict hygiene and safety practices.

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iii) Bottle capping and labeling department: This is the department where filled bottles are capped with the caps immersed in the warm water to avoid contamination and the stamped labels are manually inserted around the body of the bottles.

Figure 4:showing bottle capping section and filling section respectively

iv)Neck sealing and shrink wrapping department: This is the plant where at first the neck sealing is manually done then afterwards the shrink wrapping is done with proper adjustment.

Figure 5:showing the label shrink packager

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v)Plastic preforms blow moulding department: This is the department where usually 30 grams size performs are blown to the bottles using the following machine. The preforms size varies according to the required size of the bottle i.e. 250 ml, 500 ml, 1 l, 1.5l, 2 l, 5 l, 20 l etc.

Figure 6:showing the preforms and the blow moulding machine Bottle caps are usually made from the mixture of High Density Polyethylene(HDPE) and the LLDPE using 4 cincinnati Milacron and 2 winds or injection moulding machines.

vi)Water pretreatment plant: This is the plant where the raw water from the bore wells is treated differently before pumping it to the processing plant thus making it very suitable for human use already.

vii)Quality assurance and control laboratory: Water testing lab is very important department of the factory when it is world recognized ISO 9001:2008 certified and thus it is made sure that the water is of the ISO standards and completely suitable for the consumption. ENPHO water test kit has been provided along with the operational manual for the safety purposes.(details under the activities heading).
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vii)Storage: The stock of the finished, semi-finished goods are stored in a cold room and dispatched as perthe orders.

viii)Jar filling and sealing department: The jar filling and sealing needs to be done carefully so as to maintain hygiene and ensure the product quality.(detailed processing has been described under activities heading)

Figure 7:showing the jar filling and sealing section

5.8. Marketing chain of the company:

The marketing chain of the company over the years has been changing frequently from the middle person or retailer involved to the present one without any retailers i.e. directly from the producer to the end consumers. Some cases include following market chain: Stock point being at the factory location itself and the distributor located at the capital city Kathmandu, Nepal. The retailers were at various locations at most of the popular cities of the country. Thus the products are accessible to the consumers in two ways. Major consumers being the hotels and restaurants of the capital as well as some major cities of Nepal, they could get the product through the companys distributors as well as retailers, or directly from the factory itself.

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Market Chain at Yeti Beverages

Mother warehouse

CNFA(clearing and forwarding agent)

Stock point

Distributor

Retailer

End consumer

Figure 8:showing the market chain of the factory

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6. Internship activities:
The internship activities on daily basis have been listed out in the weekly schedule above. The tasks can be described based on the factory manufacturing system and processing cycle as below: 6.1.Demonstration and introduction to the machine: At first, each and every department the intern was introduced to for their daily activities, the operation was demonstrated properly by the department head or supervisor most of the times. Then intern was allowed to take over partially under strict supervision to maintain the In process Quality control(IPQC).

Then the activities were performed as per the production process at first then to the Quality lab section and finally to the marketing which has been listed as: 6.2.Raw materials quality control as well as responsibility: This is very important step and should be careful for that reason. Firstly, the amount of raw materials those needed to be purchased is calculated and then the order is placed. The preforms, jars, jar caps and bottle caps are weighed, graded then damaged are also recorded.

6.3. In Process quality control (IPQC): All the processes of production are carried forward according to the BPR. After the preparation of any batch, it is checked by the QA chemist. Only after the QA approval, the batch is forwarded for processing. A precise control was maintained during the process with the regular checks of batch code, volume, packaging and filling. IPQC parameters were checked as per BPRs as per the frequency by both QA and production personnel. Packaging checks: i) ii) Non-destructive checks: shape and top creases, printing, weight, tab position Destructive checks, were done.
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During the production cycle, after the performs were blown to bottles, the damaged were counted as in bottles and in preforms itself. They were noted to calculate total production per batch and thus damaged bottles and preforms were sold back to recycling or grinding department.

These produced bottles were carried to the washing department through the moving conveyor belts, the machine was turned on. The rate of washing was set and machine was monitored afterwards in case if the irregular bottles create problem in the machine performance. Main steps as an intern, learnt were:

a)Routing: the route of the production process is designed in such a way that the transportation of the materials is the minimum which is extremely taken care of.

b)Estimating: It can be called as a special type of the forecasting. To decide or preplan or guess what the new things, tools, components of the part will cost and what will be its effect on the production and demand of the product.

c)Loading and scheduling: Both of them helps in the production planning. Loading refers to the time gap for various work loads booked in advance. Scheduling(preparing time tables from the start to the end) ensures the delivery of the product whereas the other ensures the maximum utilization.

d)Dispatching: It refers to the actual issuing of the orders for performing different actions in various units for which above mentioned activities are done. Various paper works as well as graphs and charts, records are studied well and finally decision is made.

Distribution afterwards is done using big or small vehicles as per the need and route of the transportation.

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e)Follow up: Regarding the actual performance, the production cycle and efficiency of the factory can be judged so dispatcher keeps the record, feedback and counterchecks the production system considering the seniors view. f)Inspection: Its very important job under quality control and is detailed below. To inspect to know the acceptable and unacceptable product and let know the QA officer may in future decline the defects and produce better quality products.

g)Evaluation: It is a link between the control and future planning. The products of the Yeti Beverages has been evaluated by the ISO 9001:2008 and also by the DFTQC(department of food technology and quality control).

6.4.Finished product control: The very important internship activity performed was as the quality control officer which was to assure the quality of the processed water. The task was performed following the ENPHO(environment and public health organization) water test kit which is especially designed to test the drinking water[http://www.enpho.org/research-and-development/field-test-kits.html] 10 parameters to check according to the kit and ISO requirements are: i) pH ii) Temperature iii) Chloride iv) Hardness v) Iron vi) Ammonia vii) Phosphate viii) Nitrate

ix) Free residual chlorine x) Coliform test.(P/A)

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These tests were carried out in the lab daily and entered into the reports for the evaluation and future reference. In case if the results were out of standards then the batch was rejected and the plant was suggested washing.

7. Assessment of the internship:

After the completion of 45 days of internship in the beverage company of Nepal, I, as an intern feel to be more skilled, confident and capable of handling the responsibility provided in any company. I found the working environment in the factory comfortable and easy to adapt. The machine and the manual labor collaboration was shockingly balanced to provide such an amazing output without much of an error.

As the departments have been clearly described above as well as the pattern of the internship, my responsibility throughout the internship was differentiating as the week passed by. Each week I was directed to the different departments and allowed gracefully to look after the respective units under the very admirable supervision. Later on that respective week, I was fully relied upon to take over the whole responsibility as mentioned above.

This internship will certainly be influencing my future plans. I will be planning my future careers with a clear point of view now keeping on mind what might be the responsibilities and will I be able to handle it or not, also the fact that will I be adapting to the working environment or not. This activity has certainly developed my professional attics so that I can be more prepared and enthusiastic to join the food and beverages industry in the nation.

When comparing the classroom knowledge I achieved when gaining the theoretical classes, the internship has been more effective since I got opportunity to get involved practically whatever was told by the supervisor. The same things I used to write has been clearer to me after the internship as well as the mental conscience has increased leading to higher curiosity and thinking behavior. However the strictness, precautions, dos/donts and the theory, in some cases have not been followed in the company lab as used to be followed in the classes.

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8. Plant sanitation:
GMP and ISO certified plant of drinking water processing unit is the most sophisticated area. It operates at highly sanitized and hygienic condition. Each worker wears a cap, an apron, hand glove and a mask. Aseptic condition is maintained here. Giving major attention to cleanliness, CIP (cleaning in place) program is carried out here. It is done to ensure a sanitized condition of the total process line. Further, the total area of the plant is also continuously cleaned with water, detergent, combatan solution, etc. These include the cleaning of floor, glasses, tiles, wash basin, etc.

9. Waste and by-product:

By product process utilization - no Types of waste -solid, liquid and semi-solid Solid and semisolid treatment- sent to the grinding section or sold to the recyclers. Disposal of the liquid waste including water rejected from RO is directly flown to the reservoir which contains fish. Waste water treatment -no

10. R&D:
There is no research and development carried out at Yeti Beverages. Only R&D on process optimization and product stability is carried out.

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11.Conclusion and recommendations:

The in-plant training at Yeti Beverages Pvt Ltd was aimed at studying the overall process of manufacturing the pure and processed bottled drinking water along with its quality system. The GMP and ISO 9001:2008 certified plant of the drinking water has fulfilled all the criteria of an ideal plant from both sanitation and technical point of view. The chemical lab microbiological lab, IPQC lab and packaging lab working under the QA department have a team of skilled and well-trained employees, thus the quality system maintained here is dynamic. Quality is the main goal and each department from Production, QC to Storage is doing its best to provide the highest quality product to the consumers. The supportive and co-operative staffs have made a pleasant working environment here. The facilities of power, water, machineries and transport need not be exaggerated. The other facilities provided to the labors are good too. Some of the recommendations are as follows: a)A major thing that is lacking at the factory is a proper waste water treatment and management plant. It would have been better if the factory had a water utilization plant inside the factory itself. b) The time schedule could have been proper. c) It could be beneficial if the company itself manufacture the jar, jar caps, bottle caps . It was immense pleasure to perform the in-plant training at such a reputed private enterprise. The knowledge and the experienced gained here will certainly be a great help in future.

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12.Appendices: 1.

Figure 9:showing the production chart for the water processing

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2.

Figure 10:showing carbon filters and storage tank

29

3.

Figure 11:showing reverse osmosis RO machine and ozone generator

30

4.

Figure 12:showing micron membrane filter and UV sterilizer

5.

Figure 13:showing the ISO certification of the YETI BEVERAGES

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