1

Processing and Quality Assurance Project Report

Submitted in partial fulfillment of the requirements

For the degree of Master of Biotechnology
To
DR. RAVI DEVAL
By
Pooja
M.Sc., Biotechnology 4th Sem.
Under the guidance of
Mr. Ajay Sharma
Quality Head
BRINDAVAN BEVERAGE PVT. LTD., BAREILLY
In the Year-2016-17
2

ACKNOWLEDGEMENT

It is an honor for me to express my deep gratitude for those people involved in this
endeavor.

I express my deepest gratitude to Dr. Ravi Deval, Head of Department,

Biotechnology, Invertis University Bareilly, (U.P) for his valuable guidance &
blessings.
I would like to take this opportunity to thanks all those who contributed to this
report and helped me at every step.

My great thanks to Mr. K.K. CHANRAKAR (Vice President), Brindavan

Beverages Pvt. Ltd., Bareilly.

Mr. KAUSIK KUMAR MANDAL (Asst. System Manager & Kinley In

charge) of the project for guiding and correcting various documents of mine with
attention and care. He has taken pain to go through the project and make
necessary correction as and when needed.

I express my thanks to Mr. RAJ KUMAR SHARMA (H.R.), Brindavan

Beverages Pvt. Ltd., Bareilly for extending his support.

My deep sense of gratitude to Mr. AJAY SHARMA (Quality Manager) for his
support and guidance.

My special thanks to Mr. VIRENDRA KUMAR (QA Executive) and Mr.

SHIVAM RATHUR (QA Chemist) Brindavan Beverages Pvt. Ltd., Bareilly for
his great support & guidance.
Thanks and appreciation to the Quality Assurance (R.G.B) Lab Staff at
Brindavan Beverages Pvt. Ltd., Bareilly, for their full support and motivation.
I also extend my heartily thanks to my family
3

INDEX
S.NO. TOPIC NAME PAGE
NO.
1 Abbreviations 4
2 Introduction 5
3 History 6
4 BBPL 7
5 Products manufactured 8
6 Requirements of soft drink manufacturing 9
7 WTP 10
8 About WTP 11-15
9 Production line of PET 16
10 Production line of RGB 17-21
11 Bottle washer 22-26
12 Syrup manufacturing 27-33
13 Beverage base 34-35
14 CIP 36-37
15 Microbiology 38-62
16 Conclusion 63
4

ABBREVIATIONS

SOP- standard operation procedure

MMI- Master mixing instruction

WTP- water treatment plant

ETP- Effluent treatment plant

RGB- returnable glass bottle

PET- poly ethylene terephthalate

AMP- Alphonso mango pulp

TMP- Totapuri mango pulp

ACF- Activate carbon filter

PSF- Pressure sand filter

TTACF-Twin tower activated carbon filter

LLACF- lid leg activated carbon filter

RO- Reverse osmosis

5

Introduction

A soft Drink is a beverage, often carbonated, that does not contain alcohol.

Carbonated soft drinks are more commonly known as soda, pop, tonic, or soda pop

in parts of the United States and Canada, or fizzy drinks in the U.K.; sometimes

called minerals in Ireland. Beverages like colas, sparkling water, iced tea,

lemonade, squash, and fruit punch are among the most common types of soft

drinks, while hot chocolate, hot tea, coffee, milk, tap water, alcohol, and

milkshakes do not fall into this classification.

6

History of Coca-Cola-

Coca-Cola is a carbonated soft drink sold in stores, restaurants and vending

machines in more than 200 countries. It is produced by The Coca-Cola Company
and is often referred to simply as Coke. Originally intended as a patent medicine
when it was invented in the late 19th century by John Pemberton, Coca-Cola was
bought out by businessman Griggs Candler, whose marketing tactics led Coke to
its dominance of the world soft drink market throughout the 20th century.

The company actually produces concentrate, which is then sold to various

licensed Coca-Cola bottlers throughout the world. The bottlers, who hold
territorially exclusive contracts with the company, produce finished product in cans
and bottles from the concentrate in combination with filtered water and sweeteners.
The bottlers then sell, distribute and merchandise Coca-Cola in cans and bottles to
retail stores and vending machines.
7

BRINDAVAN BEVERAGE PVT. LTD.

Brindavan Beverages Pvt. Ltd. (BBPL) is one of the major Bottlers of the Coca
Cola Company in India, operating in Western Uttar Pradesh and Uttarakhand. Its
territory rights include 9 districts in Uttar Pradesh (Bareilly, Rampur, Moradabad,
Jyotiba Rao Phule Nagar, Budaun, Shahjahanpur, Pilibhit, and Kheri) and 8
districts in Uttarakhand (Nanital, Udhamsingh Nagar, Champawat, Almora,
Pithoragarh, Bageshwar, Chamoli, and Rudraprayag).

Food and Beverages Division of Brindavan Beverages offers a wide range of non-
alcoholic beverages (Sparkling Beverages), Juices & Packaged Drinking Water.

BBPL continuously support Distributors, Retailers, Traders/ Agencies in all

possible ways to ensure the availability of quality products of The Coca Cola
Company to itsesteemed consumers.

Brindavan Beverages Pvt. Ltd. brings enjoyment to the people in its territory
through its market leading brands and various community activities participate in
each year.

BBPL continuously keep on putting its best efforts to ensure that its people enjoy
their work and consumers enjoy products.
8

PRODUCTS MANUFACTURED IN BBPL

9

REQUIREMENTS FOR SOFT

DRINK MANUFACTURING
MATERIAL

1) RAW 2) PACKAGING 3) AUXILIARY MATERIAL

MATERIAL MATERIAL ACTIVATED CARBON
WATER HYFLO
SUGAR BOTTLES BLEACHING POWDER
BEVERAGE GLASS, FERROUS SULPHATE
BASE PLASTIC LIME (CALCIUM
CO2 CROWNS , HYDROXIDE)
PULP ,SAC CAP SODIUM CHLORIDE
& JUICE
FOR HOT CALCIUM CHLORIDE
FILLS
10

WATER TREATMENT PLANT

BOREWELL 1 & 2
ONLINE CHLORINE DOZING

RAW WATER STORAGE TANK

TREATED WATER SOFT WATER R O WATER(KINELY)

COAGULATION TANK

TREATED WATER SETTLING TANK

PSF 1,2&3 PSF 1&2 PSF 1

CLEAR WATER STORAGE TANK

ACF 1,2,3&4 ACF 1&2 ACF

LLACF 1A,1B,2A,2B,3A&3B SOFTNER TTACF

8 micron SOFT WATER STORAGE TANK 8 micron

Chlorine dozing
UV TREATMENT SOFT WATER STORAGE TANK 2 UV TREATMENT

5 micron 5 micron

1 micron NON CHLORINATED CHLORINATED HIGH PRESSURE PUMP

WATER FOR WATER FOR
USE IN PROCESS BOILER & RINSING BOTTLE WASHING RO 1 RO REJECT

RO 1 WATER DOMESTIC
STORAGE TANK USE

SODA ASH 3ppm

RO 2

RO 2 WATER RINSE OZO-

STORAGE TANK -NISATION TANK

MINERAL
DOZING

MIS BOTTLE RINSE

FILLED OZONIZATION
TANK 0.1 to 0.4 ppm

FILLER BOTTLE FILLING

11

ABOUT W.T.P
1) BORE WELL :- B.B.P.L. have 2 bore-wells of 250ft each supplied water whose
parameters are initially checked .

PARAMETERS:-
TASTE.
ODOUR.
APPEARANCE
P-ALKALINITY: - It is an alkalinity presence in water and mainly due to
presence of hydroxyl & carbonate ions.

PROCEDURE: =
50 ml water sample + phenolphthalein indicator

Pink color appears No color appears

Alkalinity (+) Alkalinity (-)

M-ALKALINITY :-It o known also known as total alkalinity and is due to

the presence of carbonates, bi-carbonates & hydroxyl ions in water.

PROCEDURE :=
50 ml water sample + phenolphthalein indicator + Methyl Purple

Ocean green color appears

Titrate it with 0.2N H2SO4

Blue color appears

Titre value * 20
12

TOTAL HARDNESS :-
PROCEDURE: =
50 ml water sample + Erichrome black T + Few drops of ammonia

Pink color appears

Titrate it with 0.2N EDTA

Blue color appears

Titre value * 20

Na-ALKALINITY :- Mainly due to the presence of NaHCO3,Na2CO3 & NaOH

in water.
PROCEDURE:=
````` M-alkalinity total hardness

Ca HARDNESS- take 50 ml water , add 2 mi 1 N NaOH and tablet

indicator on titration with EDTA pink color change to purple

Calculation- B.R.*20= calcium hardness

13

TOTAL DISSOLVED SOLIDS (T.D.S.)

IRON :- By EISEN TEST KIT, it is based colorimetric principle

PROCEDURE:=
Fill tubes with water.
Add few drops of thioglycollic acid in one tube.
Wait for few minutes.
Match the color change with given standard color list.
List also contain amount of Iron in (PPM) with respective to given
color

CHLORIDE:-
PROCEDURE :=
50 ml water sample +2 drops of phenolphthalein indicator

No color appears Pink color appears

Neutralize it by adittion of 0.02N H2SO4

Add 5 drops of K2Cr2O7

Titrate with 0.02 N AgNo3

Permanent red color appears

CALCULATION:=
NaCl (PPM):- (Titre value -8.2ml) * N of AgNo3 *58.44*1000/ vol of sample.
14

SULPHATE.
PROCEDURE :=
25 ml water sample +2 drops of phenolphthalein indicator

Pink color appears No color appears

Neutralize it by adition of 0.02N HCl

Add 25ml isopropanol + pinch of

Tertiary hydro-quinone indicator

Stir it properly

Titrate with BaCl2

Color changes from yellow to red

CALCULATION:=
So42- conc.= (ml of Bacl2 used -0.2) * 40

TURBIDITY (N.T.U.) :- By turbiditimeter.

2) BALANCING TREATMENT TANK (B.T.T.) :- B.B.P.L. have four B.T.T . of capacity 50kl,
50kl,100kl, 100kl, 150kl respectively. Here water is chemically treated so as to remove its
permanent hardness by converting it into temporary. After completion of this treatment raw
water is converted into treated water so as to forward it into processing unit. Following
treatments are given to water:-

CHEMICAL PURPOSE
HYDRATED LIME {Ca(OH)2} To control alkalinity of raw water &
convert permanent hardness into
temporary.
FeSO4 As a flocculating agent so as to settle
down impurities.
CALCIUM HYPOCHLORIDE{BLEACHING
AGENT) It acts as a antimicrobial agent .
15

3) PRESSURE SAND FITERS(P.S.F.) := It has 3 layer boulders, pebbles & fine sand layer
respectively. Its main function is to remove total suspended solids present in water .It should
be clean by back-washing in every 48 hrs ,the pressure of back-washing should be 5 times
more than forward water flow.
4) CARBONATION TANK:= This is mainly used so as to reduce pH of water or maintain it at
neutral which in turns reduce the p-alkalinity content of water. While treating with lime
alkalinity of water increases this is also reduces by carbonation.
5) ACTIVATED CARBON FILTERS (A.C.F.):= It also contain three layers boulders. pebbles, upper
layer of granular activated carbon. Its main function is to completely filter out chlorine
content of water .This granular activated carbon carbon also remove out particles upto 10
microns & other coloros, odour impurities by the phenomenon of adsorption. These carbon
filters are sanitized by back- washing . open cover back-washing & with steam also.
6) LEAD LAG ACTIVATED CARBON FILTERS (L.L.A.C.F):= It contain only granular activated carbon
layers. Mainly filter out pesticide content of water if present any and also finally removal
chlorine from water.
7) ULTRA-VOILET LAMP :- So as to remove microbial contamination. 12000 hrs. lamp life. UV
Wavelength 254
8) MICRON FILTER:- Total three 8 micron filter,5 micron filter & 0.65 micron filters. These filter
out minute particles remaining in water but the 0.65 micron filter is basically equipped to
remove microbial contamination if present any in the water even after the U.V. treatment.
Finally after the above following treatments and filters water obtained as a treated water
16

PRODUCTION LINE OF PET

CSD HOT FILL

PREFORM PREFORM

BLOW MOULDING BLOW MOULDING

BOTTLE WASHING CHLORINE WATER BOTTLE WASHING

COOL FILLING MIXER PASTEURIZER HOT FILLING

CAPPING CAPPING

WARMER TWIST CONVEYOR

ROLLER LABELLING COOLING TUNNEL

DATE CODING STRAIGHT LABELLING

FINAL INSPECTION DATE CODING

CARTION PACKING & CODING FINAL INSPECTION

CARTION PACKING & CODING

17

Production line of RGB

CSD HOT FILL

LOADING OF DIRTY RGB ON CONVEYOR LOADING OF DIRTY RGB ON CONVEYOR

UNCASER UNCASER

PRE- INSPECTION PRE-INSPECTION

BOTTLE WASHER BOTTLE WASHING

POST INSPECTION POST INSPECTION

COOL FILLING & CROWNERPARAMIX HEATING CHANNEL

DATE CODE PASTEURIZER HOT FILLING &CROWNER

COOLING TUNNEL
FINAL INSPECTION
TWIST CONVEYOR

DATE CODE

CASER FINAL INSPECTION

CASER
SHIPPING
SHIPPING

MARKET MARKET
18

PROCESS:-

1) The section described above is said to be paramix and it is of capacity 11kl/hour.

2) It is a section where different raw materials are mixed together and carbonated finally this
mixture in line to form carbonated soft drink.
3) Treated water is filled in tank of paramix, where it is deaerated and partially carbonated.
4) Ready syrup from ready syrup room is transferred & stored in ready syrup tank at
paramix.
5) Then water & ready syrup are received & mixed in circulatory pump where the brix of
this mixture is checked and maintained.
6) After maintaining the specific brix of mixture, it is passed in single stage plate-heat
exchanger for cooling. Method of continuously mass filling and sealing comprising
bottles used in the commercial distribution of carbonated beverages cooling uncarbonated
liquid beverage to a temperature slightly above freezing.
7) Cooled mixture is then line- carbonated at specific gas volumes as per specifications.
8) Finally prepared carbonated soft-drink is stored.
19

MAAZA

Maaza is a Coca-Cola fruit drink brand marketed in India and Bangladesh, the most
popular drink being the mango variety so much that over the years, the Maaza brand has become
synonymous with Mango. Initially Coca-Cola had also launched Maaza in orange and pineapple
variants, but these variants were subsequently dropped. Coca-Cola has recently re-launched these
variants again in the Indian market.
Mango drinks currently account for 90% of the fruit juice market in India. Maaza
currently dominates the fruit drink category and competes with Pepsi's Slice brand of mango
drink and Frooti, manufactured by Parle-Agro.
While Frooti was sold in small cartons, Maaza and Slice were initially sold in returnable
bottles. However, all brands are also now available in small cartons and large PET bottles. Of
late, the Indian market is witnessing the entry of a large number of small manufacturers
producing only mango fruit drink. Maaza has a distinct pulpy taste as compared to Frooti and
tastes slightly sweeter than Slice. Maaza claims to contain mango pulp of the Alphonso variety,
which is known as the "King of Mangoes" in India.
20

PASTEURIZER MAAZA

1. Pasteurization is a process of heating a food, usually a liquid, to a specific temperature

for a definite length of time and then cooling it immediately. This process slows spoilage

due to microbial growth in the food.

2. Pasteurizer in MAAZA basically consists of 3 main parts:

a. Heating PHE.

b. Trim Cooler.

c. Cooling PHE.

3. The Ready beverage from tanks are passed in to the Heating PHE where the beverage is

heated at 96-98 C.

4. Then the beverage passes through the Trim Cooler which takes down the beverage

temperature to 84-88C.

5. Then the beverage is ready to be filled in the P.E.T. bottles, and is passed online to the

MAAZA filler room.

6. The extra beverage (10%) passed to cooling PHE, which is then passed to the saver tank

and later recycled through Balance tank.

 21

BOTTLE WASHING UNIT

RETURNABLE GLASS
BOTTLES(RGB)

PRE-LIGHT TESTING :- FOR SORTING

OF GLASS BOTTLES WHICH ARE IN
ACCEPTABLE CONDITIONS WITH
LESS DIRT AND UNBREAKED.

SORTED BOTTLES ARE THEN SEND

TO BOTTLE -WASHER THROUGH
MOVING CONVEYER

BOTTLE WASHER = IT CONTAINS BELT OF 40 POCKETS WHICH HOLD BOTTLES OF CAPACITY

200 & 300 ml IN IT AND THEN PASSES THROUGH THESE CHAMBERS:
PRE-RINSING CHAMBER
CAPACITY OF :- 1150Kl
FUNCTION:- Bottles are rinse with forced water having pressure of 30-35 PSI from both direction to
remove heavy dirt& residual product from bottle.

SOAK CHAMBER (I)

CAPACITY OF :- 19000Kl
FUNCTION:- Contain Caustic solution of 2.0%+- 0.2 at 600+-20C.
Main used for bottle washing purpose so as to clean the bottle from both outside and inside.

SOAK CHAMBER (II)

CAPACITY OF :- 19500Kl
FUNCTION:- Contain Caustic solution of 2.8%+- 0.2 at 740+-20C.
Main compartment where bottles are cleaned and sanitized by the action of additive+ hot caustic .
SOAK CHAMBER (III)
CAPACITY OF :- 15600Kl
FUNCTION:- Contain Caustic solution of 2.5%+- 0.2 at 600+-20C.
Main used for bottle washing purpose so as to clean the bottle.

HYDROWASH CHAMBER
CAPACITY OF :- 1500Kl . TEMPERATURE = 35-400C
HOT WASH CHAMBER
CAPACITY OF :- 1600Kl TEMPERATURE = 35-400C
PRE-FINAL CHAMBER with chlorinated soft water
FINAL WASH CHAMBER with soft water with pressure of 2.5-4.3 kg/cm2
 22

THREE REAGENTS ARE ADDED IN BOTTLE-WASHER DURING WASHING.THESE ARE:-

DIVO ULTRA = ADDED TO REMOVE PREVIOUS DATE CODE PRESENT ON BOTTLES & ALSO ACT AS
ANTIMICROBIAL AGENT
DIVO AI = ADDED SO AS TO MAINTAIN PH OF CAUSTIC NEAR TO 8.0 ,BASICALLY IT IS
PHOSPHORIC ACID.
DIVO LE = BASICALLY IT IS EDTA & PREVENT DEPOSITION OF HEAVY METAL LAYER IN
WASHING CHAMBER.

CLEANED BOTTES ARE THEN

FINALLY IMMERSES OUT FROM
WASHER , WITH CAPACITY OF
600BPM,

POST- LIGHT TESTING: - TO CHECK

THE BOTTLES AFTER WASHING &
SORT OUT DEFECTIVE AND
UNCLEANED BOTTLES

UNCLEANED BOTTLES.
FINALLY WASHED BOTTLES ARE NOW
CONVEYED TOWARD FILLER FOR
BEVERAGE FILLING ALONG WITH ITS
CROWNING.

PACKEDLIGHT TESTING
-TO CHECK FINAL PACKED BEVERAGE
BOTTLES AND SORT OUT DEFECTIVE
BOTTLES IF REMAINS ANY.

CHECKED BOTTLES ARE NOW PACKED

UP IN CRATES AND DISPATCHED
 23

Bottle Washer Test

Carbonated Soft Drink (CSD Line)

Determine of P3 Stabilon Mex power. (Soak 2 & Every 4 hrs.)
Free EDTA Test (Ferrisol). (Every 4 hrs.)
Determine of Carbonate in bottle washer. (Soak 2 & 1 Week.)
Determine of chlorine. (Pre-final, Every 4 hrs. & Result-1-3ppm)
Total Hardness test. (Pre-final & Every 4 hrs.)
Determine of caustic. (Soak 1, 2 & Every 4 hrs.)
Determine of caustic Carryover. (Every 4 hrs.)
Cleaning and Sanitation for bottle washer compartment.
Caustic reduce in container.
Appearance and Odor-contain washer solution.

Non-Carbonated Soft Drink (N-CSD Line)

Divo Ultra analysis. (Soak 2 & Every 4 hrs.)
Divo LE Concentration. (Every 4 hrs.)
Methylene Blue Test. ( Starting)
Determine of Carbonate in bottle washer. (Soak 2 & 1 Week.)
Determine of chlorine. (Pre-final, Every 4 hrs. & Result-1-3ppm)
Total Hardness test. (Pre-final & Every 4 hrs.)
Determine of caustic. (Soak 1, 2 & Every 4 hrs.)
Determine of caustic Carryover. (Every 4 hrs.)
Chlorine test for Cooling turnal.
Cleaning and Sanitation for bottle washer compartment.
Caustic reduce in container.
Appearance and Odor-contain washer solution.
Mold Non-Viable in washed bottle.

Mex Power: - Acid based / Leach out of Divo Ultra: - Acid based / Leach out of
impurities and Remove date code. impurities and Remove date code.
Ferrisol: - EDTA / Heavy particles leach out. Divo LE: - EDTA / Heavy particles leach out.
Horolith: - pH Control / Acid Base. Divo AI: - pH Control / Acid Base.
24

Mex Power Test:-

PROCEDURE: =
Take 25 ml Soak 2 sample in conical flask+ add (2-3) drops of Phenolphalin indicator

Titrate with 2N Acetic acid (CH3COOH)

Until the color change from pink to colorless

Calculation
% of Caustic - B.R 0.32

Take 3ml above solution Acetic acid + add (3-4) indicator

Titrate with 0.01N Copper sulphate (CuSo4)

Until the color change from Yellow to Red

Calculation
% of Mex Power - B.R 0.10
 25

Free EDTA Test (Ferrisol):-

PROCEDURE: =
Take 50ml sample of EDTA + Total Hardness Tablet (1-2) + add (3-4) drops of ammonia buffer
(NH3)

Titrate with 0.005% Zink Sulphate (ZnSo4)

Until the color change from Blue to Purple

Calculation
% of Free EDTA - B.R 1.0

Caustic Concentration :-

PROCEDURE: =
Take 10ml Soak 1, 2 sample in conical flask + 10ml soft water

Add (2-3) drops of Phenolphalin indicator

Titrate with 1N Sulfuric Acid (H2So4)

Until the colorless

Note Reading
Add (1-2) drops of Methyl Purple indicator

Until the color change from Green to purple

Note Reading
Calculation

% of Caustic 2P-M 0.4

26

Total Hardness test:-

PROCEDURE: =

Take 50 ml Water sample in conical flask+ add 2 ml of Ammonia buffer (NH3)

Add a pinch of hardness indicator (solo chrome black-t)

Shake the solution appearance of deep Red wine color if is Blue hardness will be zero.

Titrate with EDTA solution

Until the color change from Red to Blue

Calculation
% of Total Hardness B.R 10
27

Divo LE test:-

PROCEDURE: =

Take 100 ml sample in conical flask+ add (2-3) drops of Ammonia buffer (NH3)

Add a pinch of hardness indicator (solo chrome black-t)

If Pink is present = Divo LE ve

If Purple is present = Divo LE +ve

Titrate with LE reagent

Until the pink color

Calculation
Divo LE Conc. (ppm) = B.R 95
 28

Syrup manufacturing process

Steam and treat

water Weighing of sugar and
dumping in to sugar dissolving
tank and heating up to 85C
Sugar

Empty
gunny bag Hold sugar solution at 85c
Carbon for 20min with agitation Hyflow
Hyflow

Filter press
Precoating tank

Filtration of syrup Used filter paper,

hyflow and carbon in
No spent carbon

If carbon carry over

recirculate in sugar
SDT

No

Cooling of syrup
at 10-25C
Treat water

Transfer of syrup
Transfer of treat in ready syrup
water in ready tank
syrup tank for non
sweetened syrup
Mixing of conc
Conc and and beverage in to
beverage tank as per MMI

Empty cans Make up std brix and Water addition as

and polybass volume as per MMI per water addition
table

Deaeration and
storage at 10-30C
29

Finished Syrup specification- Carbonated soft drink (CSD)

COCA COLA

Syrup manufacture for 1 unit:-

Sugar 203.225kg
Water Approx. 150Ltr
Volume of final syrup for 1 unit 300L
Brix (Fresh) 54.85
App. Density at 20C 1.25566kg/l

LIMCA

Syrup manufacture for 1 unit:-

Sugar 259.40180kg
Water Approx. 200Ltr
Volume of final syrup for 1 unit 436.75L
Brix (Fresh) 49.35
App. Density at 20C 1.22497kg/l
Weight final syrup for 1 unit 535.00050kg

SPRITE

Syrup manufacture for 1 unit:-

Sugar 241.7557kg
Water Approx. 180Ltr
Volume of final syrup for 1 unit 370.77L
Brix (Fresh) 53.15
App. Density at 20C 1.24605kg/l
Weight final syrup for 1 unit 461.9970kg
30

FANTA

Syrup manufacture for 1 unit:-

Sugar 273.90810 kg
Water Approx. 150Ltr
Volume of final syrup for 1 unit 370.89L
Brix (Fresh) 58.75
App. Density at 20C 1.27812kg/l
Weight final syrup for 1 unit 474.0445kg

THUMPS UP

Syrup manufacture for 1 unit:-

Sugar 248.19770kg
Water Approx. 250Ltr
Volume of final syrup for 1 unit 436.71L
Brix (Fresh) 47.60
App. Density at 20C 1.21545kg/l
Weight final syrup for 1 unit 530.8001kg
31

Finished syrup specification- Non-Carbonated soft drink (N-CSD)

MAAZA

Syrup manufacture for 1 unit: -

Sugar 320.0500kg
Water Approx. 300Ltr
Volume of final syrup for 1 unit
Brix (Fresh) 15.17
App. Density at 20C 1.06186kg/l
pH 3.6
Alphonso mango pulp (2B) 54.000kg
Totapuri mango pulp (2C) 306.000kg

Syrup Test: -

Sediment. (Lot change)

Floc test. (Lot change)
Color test. (Every Batch)
Test odor app. (Every Batch)
Brix. (Every Batch)
Carbon carryover. (Every Batch)
pH (Every Batch)
32

Sedimentation Test:-
PROCEDURE: =

Syrup

Check Brix (69.25)

Calculation
Formula Gm. sugar = (300100) Brix
= 433.212gm
Wight sample of syrup

Clean the container

We take distilled water

Filter the distilled water from .45 micron filter

Add water into syrup sample 800ml approx.

Sample filter from 2 = 0.8 micron of same weight

Put it into not air oven (60C-105C for 1hrs)

Less than 0.7 mg

Weight = 1 filter-0.0932
2 filter-0.0926

Sediment in Mg/Kg= Weight difference in gms 1000000

300gms solids

Filter membrane = (1) 0.0932

(2) 0.0926
= 0.0932-0.926= 0.0006
33

# Sediment in Mg/kg = 0.0006 1000000

300
=2

Floc Test:-
PROCEDURE: =

Take 800 ml syrup from raw syrup room

Brix-54A.Dvol.
54
Maintain Brix at 54C

Add Sodium benzoate (10ml)

Mix with magnate sterner and add the Phosphate acid drop by drop till the reduced pH-1.5

Packed in the bottle in dark room for 10 days

We see first result after 3 days

See final result after 10 days

Color Test:-

PROCEDURE: =

Collect the sample of simple syrup after re-circulating the filter press in a clear beaker (100ml
capacity) and cool it gradually in a water bath.

Dilute the syrup to 50C Brix for dilution to 50Brix

Adjust pH of the 50 Brix syrup to 7.0 by using 0.1N NaOH or 0.1 HCL

Set the Spectrophotometer wavelength to 420nm

34

Rinse the measuring cell with syrup and the fill with the syrup

Determine the absorption of the syrup using filtered distilled with as reference
standard for zero color.

Calculation

ICUMSA Color = Absorbance 1000

Cell length (in cm) concentration (gm. /cm3)
35

BEVERAGE BASE

It is also the main requirement for the production of carbonated soft drink. The contents of this
beverage base is not mentioned here because it is confidential matter of the company. But all
beverage base should have labels bearing the name of flavor , Ex :- fanta apple. Therefore
every flavored carbonated soft drink (C.S.D.) has their own specific beverage base with their
addition order .These bases are in two forms:-

(a) Dry base = store at 11-30oC.

(b) Concentrate = store at 4-100C. Some of them are:-

1A
LIMCA =
BEVERAGE BASE :- PART 1 1A (SOLID)
1B
PART 2 ( LIQUID)

FANTA ORANGE = 1B
BEVERAGE BASE :- PART 1 (SOLID)
1C

1D

PART 2 (LIQUID)

COCA-COLA=
BEVERAGE BASE :- PART 1 (LIQUID)

PART 2 (LIQUID)

THUMS-UP =
BEVERAGE BASE :- PART 1 (LIQUID)

PART 2 (LIQUID)
36

SPRITE= 1A
BEVERAGE BASE :- PART 1 (SOLID)

1B
PART 2 (LIQUID)

KINLEY CLUB SODA=

PART 1 (SOLID)

MAAZA= 1B

PART 1 (SOLID)

1K
AMP
TMP
MMPO=
1A

PART 1 (SOLID)

1C
PART 2 (LIQUID)
ORANGE JUICE & ORANGE PULP

MMNF=
1A

PART 1
1C

1 D

1E
PART 2 ( LIQUID)
FROZEN LEMON PREPARATION
 37

CLEANING IN-PLACE
CIP

5 STEPS:- 3 STEPS:- 6 STEPS

a) PRE-RINSING. a) CLEANING PROCEDURE a) COLD WATER RINSING
b) HOT CAUSTIC b) HOT WATER SANITATION. B) HOT CAUSTIC CLEANING
CLEANING. c) HOT CAUSTIC CLEANING & C) COLD WATER RINSING
c) CLEANING SANITATION. D) HOT WATER SANITATION
E) HOT ACID SANITATION
PROCEDURE.
F) COLD WATER RINSING
d) HOT WATER
SANITATION.
e) FINAL RINSING.

Steps for CIP is basically depend on the flavor of beverage produced so as to prevent flavor
carry over in next flavor changed batch and CIP also ensured prevention from various microbial
contamination which directly ensured quality and shelf-life of final beverage.
If the flavor of presently produced beverage is so pungent then there is a 5 steps CIP occur on
changing of flavor. The order of pungency is:-

Thums-up > Coke > Fanta orange > Sprite > Limca

5 Steps cleaning & sanitation must also be used prior to production, if filling line is not used
continuously for a period of 72 hours. Also when there is any flavor carryover is observed even
after 5 steps CIP then hot treated water flushing for 20 mins or more to ensure no flavor
carryover.

5 STEPS CIP FOR CSD:-

1. Rinse with treated water for 10 mins.
2. Recirculate a hot caustic solution (1-1.5%) at 60-770C for 15 mins. Rinse with treated water for
10 mins.
3. Recirculate or flush hot treated water at 850C for 15 mins.
4. Final rinse with product water for 10 mins or more until complete removal of all caustic traces
is ensured.
38

3 STEPS CIP FOR CSD:-

A) CLEANING PROCEDURE
Rinse with treated water for 5mins.
Recirculate a hot caustic solution (1-1.5%) for 10 mins.
Rinse with product water for 10 mins or more until complete removal of all
caustic traces is ensured.

B) HOT WATER SANITATION

Rinse with treated water for 10 mins.
Recirculate or flush treated water at 850C for 15 mins.
Final rinse with product water for a 5 mins.

C) HOT CAUSTIC CLEANING & SANITATION

Rinse with treated water for 5 mins.
Recirculate a hot caustic solution (1-1.5%) at 850C for 15 mins.
Final rinse with hot product water at 850Cfor 10 mins or more until complete
removal of all caustic traces is ensured.
39

Microbiology

SAMPLE AREA ANALYZED FOR LIMIT

RAW WATER COLIFORM nil

TOTAL PLATE COUNT 500/ml

SOFT WATER COLIFORM nil

TOTAL PLATE COUNT 25/ml

TREATED WATER COLIFORM nil

TOTAL PLATE COUNT 25/ml

RINSE WATER AFTER CIP TOTAL PLATE COUNT

(TANKS, PARAMIX, FILLER) YEAST AND MOULD <20/ml

HOT FILL CIP TOTAL PLATE COUNT

YEAST AND MOULD

CSD PRODUCTS YEAST AND MOULD <10/ml

HOT FILL PRODUCTS TOTAL PLATE COUNT 5/2ml

YEAST AND MOULD 2/2ml
HRM nil
TAB nil
40

MICRO ORGANISMS PRESENT IN BEVERAGE

Micro organisms are present in Beverages

Most Common:
Yeast

Molds

Bacteria

Less Common

Algae

Protozoa

How small are Micro Organisms

The relative sizes of different micro organisms:

Molds & yeast - 8micron to 10 micron

Bacteria - 1micron to 3 micron

Viruses - 10 nmto 100 nm

Molds and yeasts are Eukaryotic : they have a nucleus.

Bacteria are prokaryotic : they do not have a defined nucleus.
41

YEASTS

Yeast Spoilage attributed to many factors including:

Poor hygiene.

Poor quality raw ingredients.

Incorrect manufacturing practices.

Yeast Spoilage

Two common yeast that cause spoilage in beverage are:

Saccharomyces

Zygosaccharomyces (may be preservative resistant)

Yeast reproduce in two ways

o Budding

o Binary Fission

What does yeast spoilage look like

May Produe large amount of carbon di oxide and sometimes

swollen packages.

Product may have off taste.

Spoil product may have a sediment.

May Cause product to change colour.

42

MOLDS
Mold spoilage attributed to many factors including:
Poor hygiene (especially poor air quality).
Poor quality of raw ingredients.
Incorrect manufacturing practices.

Common molds that cause spoilage in beverages are:

Aspergillus
Penicillium
Byssochalamys, Neosartorya, Fusarium

Molds produce several structures.

Hyphae
Sporangiophore, Conidiophore
Spores:
Asexual: sporangiospores, conidia
Sexual : ascospore, zygospores.
Heat Resistant spores: Chlamydospores, Acsospores.

What does mold spoilage look like

Formation of mycelial mats on the surface and inside tha product.
Production of pectic enzyme resulting in separation and product.
Production of mycotozins.
Off-tastes and color changes.

Important spoilage organism: Heat resistant molds

Byssochalamys, Neosartorya and Talaromyces (ascospores)
Paecilomyces variotii, Fusarium oxysporum, (Chalamydospores)
Heat resistant spores survive pasteurization and hot fill processes and can than
germinate and grow in some of the product.

Source (HRMs)
Soil: Post harvest contamination of fruit/sugar.
Dust: contamination of packaging.
Air: Contamination of filling area.
43

BACTERIA

Poor hygiene (especially poor air quality).

Poor quality of raw ingredients.

Incorrect manufacturing pratices.

Bacteria Spoilage:

Greater range of bacteria will spoil low acid beverage.

Common bacteria that cause spoilage in acidic beverage includes:

Acetic Acid bacteria.

Lactic Acid bacteria.
Spore forming Bacteria.
44

ACETIC ACID BACTERIA

Obligate aerobes. Gram negative, oxidase negative, rod shaped organisms.

Capable of converting ethanol to acetic acid.

Include acetobacter, Gluconobacter etc.

pH growth range 2.5-7.0

Optimum temperature for growth 25-30c

Commonly found in soil, water and fruit.

Spoilage of still beverage possible.

Spoilage characteristic include turbidity and sour odour.

Growth limited in sparkling products.

45

LACTIC ACID BACTERIA

Microaerophillic: gram positive, non-spore forming rods or coccobacilli, catalse-

negative.

Produce lactic acid as the major end product during the fermentation of carbohydrate

(homofermentative)

Production of lactic acid, acetic acid, ethanol and carbon di oxide (heterofermentative)

Commonly found on tha skin of fruits and soil.

pH growth range 3.5-10.5

Optimum temperature for growth 30-40C

Spoilage of sparkling still juice containing product possible.

Spoilage characteristics include sour/acid odor, diacetyl off flavour and a cloudy

appearance.
46

BACTERIAL SPORES:

Bacillus

Alicyclobacillus

Clostridium

Sporolactobacillus

What does bacterial spoilage look like

Product may look like hazy or cloudy but it is sometime hard to see bacterial spoilage.

Product may have distinctive off taste or odor.

In some case gas may be produced.

47

Common method for microbial testing of

Beverage
Topics Covered in this section

o Growth method for microbiological abalysis.

o Liquid and solid media.

o Presence absence testing.

o General Purpose media.

o Selective media.

o Cell counting and colony forming unit.

o The three main methods :

Membrane filtration.
Pour plating.
Spread plating.
Other methods.
Streak plate.

o Direct microscopic examination

48

Growth Methods:

Analyze samples by recovering/reviving, growing and counting the micro organisms found in the
samples.

Indirect Methods:

Measuring chemicals produced by micro organisms, sometimes these chemical are called
metabolites and are specific to the type of micro organisms

Liquid media or Broth:

There are many types of broth media that can be tailored for specific requirement:, for
example:
Commercial sterlity broth used by concentrate plant to test beverage bases is formulated
to only allow the growth of yeast and inhibit the growth of bacteria.
Orange serum broth contains components from orange juice that encourage the growth of
yeast found in orange fruit.

Solid Media also called agar media:

Agar is a polysaccharide that cause media gel and solidify.

49

Many solid media are made by adding agar o broth media.

Agar provide a solid surface that allow growth of micro organisms.
Growth on solid media allows us to get a micro organisms count.

At coca cola we generally use two categories of media..

1) General purpose media:

Use to isolate as many microbes as possible.

Cannot isolate all organisms because some organisms have special requirements.

Contain meat and/or vegetable extract as nitrogen source.

Contain sugars such as glucose as carbon source.

Often contain buffers to prevent build up of inhibitory acids.

Examples that we use include both liquid and solid media:

Typtone glucose extract agar/broth (TGE)

Nutrient agar/broth
Heterotrophic plate cout agar/broth

2) Selective Media:

o Liquid or solid.

o Contain chemicals to inhibit the unwanted part of a mixed population.

Sodium sulphide in endo agar inhibits gram positive bacteria.

The acid in acidified OSA inhibits the growth of non-acidified bacteria.

Example: M-endo, Cetrimide agar.

50

Some examples of media:

Mesophillic count
Plate count agar
TGE

Yeast and mold

M-green
Orange serum agar
Malt extract

Coliforms
Tergitol
M-endo
Chromocult

Other media that we use.

o Lactic acid bacteria.

MRS medium
Rogosa medium

o Pseudomonas ageruginosa

Cetrimide agar

o Sulfite reducing clostridia

51

Tryptose sulfite agar

We use broths and agars in several different

Microbiological techniques:

o Membrane filtration.

o Pour plate

o Spread plate
52

Membrane Filtration

Only for filterable samples.

Samples are filtered through a sterile membrane and incubated.
Method
Large volume (10-250ml) filtered through a membrane.
Microbial cells retained on the surface of the membrane filter
Membrane is aseptically transferred to a petri dish that contains medium and incubated at
the appropriate temperature and colonies counted

Pour palte

Can be used for both filterable and non filterable samples.

Method
Samples is aseptically transferred to an empty petri dish
Molten agar at about 45C is asepically poured into the dish on top of the sample within
20 minutes.
Sample and molten agar mixed together by gently swirling of the petri dish. This evenly
distributed the cells through the agar
Agar in petri dish allow to solidify
Petri dish incubated for appropriate time/ temperature and colonies counted.

Spread plate

Can be used for both non filterable and filterable samples.

Aseptically pipette 0.1ml of dilution onto plate .
Use sterile spreader to spread the sample evenly across the plate.
Allow plate to dry
Invert and incubate the plates
53

Streak plate

For separating out micro organisms.

Dilution series on a plate.
Allow for easier visual recognisition
Used to purify or check purity

Using heat to preserve beverage

Ways to Preserve Beverages

1) Reduction in water activity.

Carbonation.
Reduction in tempertaure.
Chemical preservation.

2) Preservation by heating.

Heating beverges to kill micro organisms can be divided into two process categories:
Pasteurization
Heating of the product to temperature between 60C-100C.
This temperature is normally sufficient to kill vegetative cells of micro organisms, non
spores forming micro organisms and most asexual spores of mold.
54

Temperature above 100C(Ultra high temperature or UHT)

Heating of the product to temperature above 100C to kill bacterial spores and some
thermally resistant mold spores.

Commercial sterility:
Condition achieved by application of heat , irradiation, high pressure or other processes alone or
in combination with other ingredients that cause the beverage to be free of micro organisms
capable of reproducing in the beverage under normal non-refrigerated condition of storage and
distribution.

Temperatures Used

Pasteurization for conjuctional fill, hot fill and antiseptic fill or high acid product:

90-95C for 15-23 seconds.

Tunnel Pasteurization of high acid product:

75-85C for 300-600 seconds.

UHT for aseptic fill of low acid product:

130-142C for 4-30 seconds.

Retort of low acid products:

120-130C for 300-600 seconds

55

Factors influencing growth of

micro organisms in beverage

1)Intrinsic factors

Nutrients

Water activity

pH-buffering

Carbonation

Preservative and other anti microbials.

2)Extrinsic factors

Temerature :

pychrophiles

Pyschrotrophs

Mesophiles

Thermophillus

Thermoduric

Air
Humadity.
56

Gas atmosphere

Aerobes : Pseudomonas

Microaerophillus(microaerobes) : Lactobacillus spp.

Facultative anerobes : Enterobacteriaceae, fermentative yeasts

Anerobes : Clostridium

Using preservatives to control the growth of

micro organisms

Why do we preserve food?

Extend shelf life
Reduce wastage
To ensure a quality product for our consumer
Make food purchase and storage more convenient for consumer

The most common chemical preservative that we use :

Organic acids
Benzoic acid
Sorbic acid
Sulphur di oxide
57

Benzoic acid
Most effective against yeast but also against molds and lactic and acetic acid bacteria.
GRAS status
Concentration used 150ppm
Narrow pH range of antimicrobialaction 2.5-4.0
Tolerated by some micro organisms.

Sorbic acid
Affect mold spore germination, spore outgrowth, mycelium growth, prevent bacterial
endospore germination and disrupts cell walls
Wider pH range of anti microbial action than benzoic acid.
GRAS status
Concentration to be used 100-250ppm
Tolerated by: Bretanomyces, Candida , Saccharomyces. Zygosaccharomyces,
Penicillium.

Sulphur di oxide
Used as a gas and as a variety of salts . E.g metabisulphites.
Exists in different forms as pH changes.
Powerful efect on enzyme
Most effective against bacteria
May have a pungent odor
May produce an allergic reaction.
Generally 8x more effective than benzoic and sorbic acid.
58

An introduction to water microbiology

Microbiological contamination caused by

Different groups of microbes.

Bacteria
Indigenous bacteria (Pseudomonaceae , Acinetobacter spp.)

Indigenous saprophytic species(Enterobacter spp.)

Human pathogenic containments(Salmonella spp.)

Fecal containments(Escherichia spp.)

Yeast and mold

Parasites

Algae

Viruses
59

Which micro organisms are we concerned about?

In water , some of the main harmful or pathogenic bacteria include:

Vibrio cholerae

Salmonella spp.

Shigella spp.

Yersinia spp.

Key microbiological parameters for water quality.

Heterotrophic palte count/total count

Total coliforms

Escherichia coli and thermotolerant coliforms

Fecal Streptococci

Pseudomonas aeruginosa

Sulfite reducing anerobes

60

Conclusion

Based on Interbrand's best global brand 2011, Coca-Cola is the world's most

valuable brand. Pepsi, the flagship product of PepsiCo, the Coca-Cola Company's

main rival in the soft drink industry, is usually second to Coke in sales.

The Coca-Cola Company only produces a syrup concentrate, which it sells to

various bottlers throughout the world who hold Coca-Cola franchises for one or

more geographical areas. The bottlers produce the final drink by mixing the syrup

with filtered water and sugar (or artificial sweeteners) and then carbonate it before

filling it into cans and bottles, which the bottlers then sell and distribute to retail

stores, vending machines, restaurants and food service distributors.

61