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DEDICATION
Dedicated to Holy Prophet Hazrat Muhammad (S.A.W) and the followers My
Parents; and Teachers
(Light in the darkness of life)
ACKNOWLEDGEMENT
All Praise to Almighty Allah, the most Beneficent, Gracious, and Merciful and
omnipresent without whose help I am unable to accomplish any objective of my life and
who enables, awarded courage and help me in every field of life especially in the
completion of this report.
I am thankful to Dr. Tahir Zahoor (Director General National Institute Of Food Science
And Technology)
I am extremely thankful to Dr. Moazzam Rafique Khan for allowing me to do
Internship at PUNJAB BEVERAGES CO. (PVT) LTD Faisalabad.
I am also thankful to Mr. Shafqat (G.M Production), Mr. M Nawaz (Dupty QCM), Mr.
Hamid , Mr. Umair and Mr. Farooq, Mr. Azeem
For their kind suggestion and sympathetic attitude completing this internship
Abstract
This report is the integration of my practical and theoretical efforts that I
have done in the Pepsi Co. limited Faisalabad unit. This reports my all the
experience and the knowledge that I have gain in the factory. I have tried my
level best to mention all about my stay along with the theoretical knowledge
of the concerned department. Suggestions and Recommendations to PEPSI
Co. are also an important component of this report.
INDEX
INTRODUCTION
1. Origins of Pepsi cola.…………………………………………………………….5
2. Pepsi cola trademark…………………………………………………………….5
3. Brands…..………………………………………………………………………...6
4. Layout of the Factory…………………………………………………………....6
WATER TREATMENT
5. Introduction……………………………………………………………………...7
6. Parameters for Water in PBC…………………………………………………..7
7. Water Treatment Process…………………………………………….....……....8
8. Treated Water Range…………………………………………………………..11
9. Tests for Water Treatment Plant……………………………………………...11
SYRUP ROOM
10. Purposes of Syrup……………………………………………………………....13
11. Flow Diagram of Syrup Preparation…………………………………………..14
12. Preparation of Syrup for Different Brands…………………………………...15
13. Test Performed for Syrup……………………………………………………...15
CLEAN PROCESS C.I.P
14. Processes for Glass Bottles……………………………………………………..17
15. Processes for PET Bottles……………………………………………………...18
16. Process for Bottles Washing…………………………………………………...19
PRODUCTION
MAIN LAB (Quality Control)
17. Apparatus used in Main Lab………………………………………………….20
18. Tests of Main Lab……………………………………………………………...20
19. Quality Control Department is Responsible………………………………....21
AQUAFINA
20. Mineral Water Processing……………………………………………………..24
21. Tests for checking Total Hardness in Minral Water………………………...26
SWOT ANALYSIS………………………………………………………………….27
Chapter No.1
Introduction
1.1 Pepsi
Pepsi is a carbonated soft drink that is produced and manufactured by Pepsi Co.
Invented in 1998 and introduced as “Brand `s Drink”. It is later renamed as Pepsi-Cola in
June 16, 1903
1.2 Origins of Pepsi cola
It was first introduced as brad’s Drink in burdett, North Caeolina in 1898 by Caleb
Bradham, who made it at his pharmacy where the drink was sold. It was later named
Pepsi Cola, possibly dye to the digestive enzymes pepsin and kola nuts used in the recipe.
Bradham sought to create a fountain drink that was delicious and in digestion and boost
energy.
1.3 Pepsi-cola trademark
1.4 Slogans
First of world
1939. 1950 “Twice as Much for a Nickel”
Last of world
2012 were there’s Pepsi, there’s Music. Use for the 2012 super bowl commercial
featuring Melaine Amaro.
First of Pakistan
1990-1991 “Yehi Hai Right Choice Baby UH HUH” (Meaning) this is the right
choice baby UH HUH.
Last of Pakistan
2011 “Dunya Hai Dil Walon Ki” Meaning World is for lovers by Ali Zafar.
Chapter No.2
Water is basic to the finished beverage. Like flavor, it is an integral part of the
drink. In the beverage. it is the vehicle or liquid portion that carries the sugar, flavor, acid,
color and CO2. Over 85% of total volume is water. Water must be of sufficient quality to
maintain the correct balance of flavoring ingredients and at the same time not contribute
substances, which will affect the taste or appearance of the drink. Adulterates such as
microorganisms, suspended particles and other impurities may be present which must be
needed to remove. In addition, alkalinity is reduced to a set level, water should be free
from undesirable such types of things and added chlorine. PBC Faisalabad takes its water
from turbine. To meet established specifications water treatment systems are used.
Water is the major ingredient of beverage. Pure water contains 11.88% hydrogen
and 88.02% oxygen by weight and is odorless, colorless and tasteless. Water is necessity
for human body. Primary function of water is that it carries ingredients of beverage.
Water obtained from ground may contain a high amount of total dissolved solids, high
alkalinity, turbidity, mineral and microorganisms, which may affect the quality of finished
beverage. Water is purified and treated to make it according to required standards.
If alkalinity is the more it will be difficult to set the pH of the beverage product
1. High microbial growth.
2. if solid impurities are more then brackish taste will be percept in the product.
Specially if chlorine is more than the product will have a medicinal taste and color
of the product will be bleached
Chlorine Nil
Sulphate Nil
Ph 8-9
Iron Nil
Chlorine function
1 To kill m.os.
Lime function
1 PH rise
2 To reduce the alkalinity
(f) POLISHERS
The filter that is connected in the treated water line after the carbon purifier is called the
water polishers. This filter remove small particle of rust or turbid material that may have
been picked up in processing the water. It removes
micro particles of foreign matter from the water and make the water crystal clear. The
filtering media in these filters are cloth, prepared cotton, asbestos or paper. Sometimes
combination of these material is used in these water polishers. There are three basic
designs in general use, the flat disc, the cylindrical cartridge, and the multiple cartridge.
For the filter to operate as its best efficiency, the filter media should be change at frequent
schedule intervals. Then water passes from polishers. Polishers are used is 5 micron
spools means the poor size of polishers is 5-micron. The filter remove small particles of
rust material that have been picked up in processing the water. It removes the micro
particles of foreign matter from the water that make the water crystal clear
clear T.O.A. Then goes to polishers for further purification. Water is passed from UV
light to kill m. os and that water should be prepared for final beverages. At this stage
check the required parameters.
(k) UV Light
In this process, ultraviolet rays used for the removing or killing
of microorganisms.
M-Alkalinity <50
Total Hardness <70
Total Dissolve Solids <500
Chlorine Nil
Iron Nil
Regents
1. Sodium thiosulphate
2. Phenolphthalein indicator
3. Methyl purple
4. Sulphuric acid
Procedure
1. Take 100ml water sample (sand filter) in beaker.
2. Add 2-3 drops of sodium thiosulphate.
3. Add 2-3 drops of phenolphthalein indicator.
It give green color and titrate against sulphuric acid N/50 end
point is colorless.
4. Note the reading this is p-alkalinity.
5. Add few drops of methyl purple indicator
6. Green color will appear.
7. Titrate against sulphuric acid N/50 and purple color appears.
8. Note the reading.
9. This is M –alkalinity.
PREPARED BY
Roll No Husnain Rasheed
2015-ag-6673
11
2.6.3 PH Test
Procedure
1. Take sample in a beaker
2. Rinse the electrode of the ph meter with water.
3. Dip the electrode in water sample.
4. Check and record the PH value of water.
5. PH of water should be 8-9.
Procedure
1. Check the water appearance against white background light.
2. In appearance we check color.
3. Check the same sample for taste and smelling.
4. Classify any off taste and off odor.
Chapter No.3
Syrup Room
In syrup room, the syrup for the final beverage is prepared with the help of water and
sugar. Some heat exchangers and filters are also used. The description of the processes,
being used in syrup room is mentioned as
3.1Purposes of Syrup
To upgrade the quality of refined sugar by the treatment of with activated carbon
at the elevated temperature to kill bacteria and, especially pathogenic bacteria and de-
coloring of syrup.
PROCEDURE
1) Take a sample 30ml
2) Add1 drop of HCL.
o
3) Place into water bath at 90 c temp for 45 mints
4) Cooled the sample.
5) Then check the brix on refractometer.
Chapter No 4
4.2 The Complete Chart of all the Processes for Glass Bottles
4.3 The Complete Chart of all the Processes for PET Bottles
First, the empty bottles are put on the running conveyor. Conveyor is in the moving state
with the help of pulley and gear system. Point to be noted that soap is put on conveyor
and boiled water below the conveyer melts the soap, creating its foam its foam on
conveyer thus bottles smoothly pass on it and not fall
In next step bottles pass from both side of the of light screen
on light conveyor, thus operator checks either is any breakage, is printed
monogram on bottles, so that pick those bottles and remaining bottles reach
the table conveyer.
Now machines put the bottles in tank no: 1 once at a time.
There are pre-rinse jets in first tank. It has treated with water coming from
tank no: 4 through carry over pump. Tank no: 1 has only soft water. The water
is replaced on weekly basis.
After initial washing bottles enter in 2nd tank which is big
size than 1st tank. Pump is attached with caustic tank which suck water
(caustic mixed) from it and after passing from filter this water falls on jets.
Jets through water with pressure inside the bottle for washing.
Tank no: 3 which is big size than tank no: 2 and has caustic
in it. It is used to clear washing and appearance and used to remove date from
bottle. Its remove impurities, straws, bees’ ets from water.
Now bottles enter tank no: 4 which have only soft water in it. Temperature is
rd o
maintained from bottles coming in it and by the wall of 3 tank at 45-55 c.no use
of steam pipe line for temperature. When bottles are near to come out from
washer, treated water is used to wash from inside at the end of process.
4.5 Production
In the plant, syrup (from syrup tanks) and water (from water treatment) is mixed at a
specific ratio called flow mix. The mixture then moves to carbon cooler where
carbonation of product i.e. absorption of CO2 in the syrup at low temperature is done. It
then moves to filler where product is filled in empty bottles and crown caps are put on it.
The final product moves towards packing machine through conveyer however most of the
time bottles are packed into cases manually.
Chapter No.5
Equipment
CARBO QC AND PFD APPARARUS
Equipment
Funnel, vacuum pump, beaker 250ml, refractometer
Procedure
1. Take the filled bottle from the production line and remove the
crown and wash the funnel using some beverage from the bottle.
2. Close the funnel valve and fill it with 200ml beverage. Seal the
funnel by cap of vacuum pump.
3. Switch on the pump and start the stop watch, slightly open the
funnel valve to left the air sucked by the pump.
4. The vacuum sucked the co2 from the beverages or
“decarboxination” is done for 10 mints app.
5. Stop the stop watch and switch off the vacuum pump.
6. Take the sample on spoon and put on the rafractometer.
7. Note the brix.
CROWN TESTER
It is done by the crown cork tester. A sample crown is passed through this tester
and is observed that cork is passed or passed or not passed according to standards. If
there is fault then, it is advised to mechanical section to reduce this fault.
Procedure
1. Bottle is adjusted above the torque.
2. And when green signal show press ok.
3. Screen show zero value.
4. Value will appear on screen
5. That will be torque value.
6. The value of torque should be 9 to 17.
7. Torque is checked after 45 mints.
Calibration
Incoming raw material
testing In process testing
Finished goods testing
Market complaints
handling Market rejections
Customer rejections
Trade sampling
Quality testing of CO2 plant and Boiler
Chapter No 6
AQUAFINA
Introduction
Water is the necessity of our daily life, it’s so important for us that we need clean, safe
and sanitary water every day, and usually there’s a stricter inspection standard in the more
advanced country. There are two kinds of drinking water in the market. One is the natural
water, which is called mineral water. The other is processed water coming from
underground or from the pipe of water plant, which is called R.O. water, space water or
pure water. Mineral water comes from natural springs. It contains a lot of various kinds of
chemical goods such as potassium, magnesium and calcium, which are healthy to our
body. After the water is filtered and sterilized properly, it’s our first choice to use it.
However, the shortcoming is that the source of mineral water is limited. On the other
side, pure water doesn’t contain any nutrition, but it’s easy to be obtained and very clean
after being processed. It tastes good with PH value 5-7 that’s the reason why people like
it very much. Pure water is processed through different stages of a filter system such as
sand, carbon, and Reversed Osmosis System. The water is passed
Page 49 from 5 microns through 1 to 0.2 microns’ filter. After that, pure water can be
filtered to remove harmful materials with an efficiency of 96%.
Processing mineral water from underground water resource or other resources goes as
follows.
1. Motor pump is used to draw water from theses sources or source which is
transported to the source water reservoir. Coagulation chemical is added to
remove the settled colloidal and suspended materials contaminated in the water.
Water is then sterilized using oxidants like chlorine or other chemicals to kill
harmful bacteria and microorganism.
2. Filtration, using filtration system like Quartz Sand Filtration System gives good
purifying results. After purification water contains very little number of
suspended solids.
3. For further purification, water is absorbed on the activated carbon which absorbs
most pollutants dissolved in water. This also helps in the removal of the odors and
helps in improving the flavor of the water.
4. After being purified water softening is done by passing water through the tank
containing sodium ion. The tank consists of resin pellets and the softening is
done by ion exchange method. Apart from this method reverse osmosis process is
also used for obtaining pure water. In this process water is purified by using semi
permeable membrane. Purified water is sterilized or disinfected and then packed
for market.
Total hardness
Reagent
Buffer 1ml to 2ml
T.H indicator tablet 1
Water sample 100ml
EDTA (ETHYLENE DI AMINE TETRA ACETATE) for requirement
Procedure
Get sample 100ml then add 2ml or 1ml buffer in sample. Now add a half tablet of T.H
indicator and mix it thoroughly. Then the colour of sample is changed in purple and then
add dropwise of EDTA solution in sample. Then the colour is converted to light blue
colour then check the quantity of EDTA solution. For the reading use formula which is
under
Formula Reading × 10 =T.H
Ozone Test
DPD Tablet
Take 5 ml sample and then add the DPD Table powder. Then the sample colour is light
pink. Then compared with standards 0.2 to 0.4.
Chloral Test
Take 2 ml sample and then add few drops of Ortno Tolodine (Strength 0.5%) then the
colour of sample s yellow. For getting the reading we compared the colour of liquids
standard colour calorimeter. Normally the quantity of chlorine in water is 2 to 2.5.
Alkaline Test
Take 100 ml sample and add few drops of the methylie purple indicator or phonphthlein.
And compares with standers ozone Metter.
SWOT Analysis
MY VISION OF PEPSI CO
Pepsi Co. is the world leading process industry that provides not only the quality
product but also satisfaction to the customers also. Pepsi Co. provide good environment
to the employee’s and bright exposure for the professionals. So, it has become a sign of
proud for the whole Faisalabad region.
COMMENTS