Project Report on Industrial Visit For Bisleri

Project Report on Industrial Visit for Bisleri

Details of Visit Name of the Company Date of visit Duration of Visit Address : Parle Product Pvt. Ltd. : : :

Product Manufactured Name/Designation of the Concerned

: Mineral water :

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Project Report on Industrial Visit for Bisleri Index

Sr.No

Contents

Page No.

Introduction About Company Products & Services Plant Layout 6-7 7-9 10

Manufacturing Process Input Process Output 11-13 14-17 18

3 4

Observation /Suggestions Opinion about Industrial Visit

19 20

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Project Report on Industrial Visit for Bisleri

List of Tables

Sr.No 1. 2.

Name of Table Comparative study of Chemical Parameters Pre-form Size

Page No 9 14

List of Diagram

Sr.No 1. 2.

Name of Table Plant layout Water treatment process diagram

Page No 10 14

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Project Report on Industrial Visit for Bisleri

1. INTRODUCTION Introduction to Bisleri

Mineral Water under the name 'Bisleri' was first introduced in Mumbai in glass bottles in two varieties - bubbly & still in 1965 by Bisleri Ltd., a company of Italian origin. This company was started by Signor Felice Bisleri who first brought the idea of selling bottled water in India. Parle bought over Bisleri (India) Ltd. In 1969 & started bottling Mineral water in glass bottles under the brand name 'Bisleri'. Later Parle switched over to PVC non-returnable bottles & finally advanced to PET containers. Since 1995 Mr. Ramesh J. Chauhan has started expanding Bisleri operations substantially and the turnover has multiplied more than 20 times over a period of 10 years and the average growth rate has been around 40% over this period. Presently Bisleri has 8 plants & 11 franchisees all over India. Their presence covers the entire span of India. Bisleri commands a 65% market share of the organized market. Bisleri value their customers & therefore have developed 8 unique pack sizes to suit the need of every individual. Bisleri is present in 250ml cups, 250ml bottles, 500ml, 1L, 1.5L, 2L which are the non-returnable packs & 5L, 20L which are the returnable packs. Till date the Indian consumer has been offered Bisleri water, however in effort to bring new refreshingly, Bisleri has introduced Natural Mountain Water - water brought from the foothills of the mountains situated in Himachal Pradesh. Hence Bisleri product range comprises of two variants: Bisleri with added minerals and Bisleri mountain water.

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Project Report on Industrial Visit for Bisleri Products

Mainly the Bisleri product range comprises of two variants: 1. Bisleri with added minerals 2. Bisleri mountain water. 1. Bisleri with added minerals Bisleri Mineral Water contains minerals such as magnesium sulphate and potassium bicarbonate which are essential minerals for healthy living. The not only maintain the ph balance of the body but also help in keeping human body fit and energetic at all times. Bisleri with added minerals is also put through multiple stages of purification to ensure the elimination of all forms of bacteria. This makes the water to drink completely safe to consume. Bisleri with added minerals is available in 250ml cups, 250ml bottles, 500ml bottles, 1L bottles, 1.5L bottles, 2L bottles and 5 and 20L cans. 2. Bisleri mountain water Bisleri Natural Mountain emanates from a natural spring, located in Uttaranchal and Himachal nestled in the vast Shivalik Mountain ranges. Lauded as today's 'fountain of youth', Bisleri Natural Mountain Water resonates with the energy and vibrancy capable of taking you back to nature. Bisleri Natural Water is bottled in its two plants in Uttaranchal and Himachal Pradesh. and is available in six different pack sizes of 250ml, 500ml, 1L, 1.5L, 2L and 5L. The water that almost descends from the Gods: Vedica Natural Mountain Water comes to in all its untouched purity, right from its source. Gushing from an aquifer with intense pressure, the natural mountain water is pushed above the ground surface to a height of 5 meters above ground level, powerfully and consistently. The underground geological origin guarantees that there is no external Contamination, since the mouth of the water source is covered from rocks on all sides. Besides, being naturally fortified with silica, the spring is naturally free form any Microbial infection or pollution. Vedica Natural Mountain Water is also low on sodium, making it the perfect choice for the health conscious. It
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Project Report on Industrial Visit for Bisleri

has a high proportion of sulphates, which work as natural detoxifying agents. And its clear, sweet taste proves that it is free of calcium carbonate and magnesium carbonate salts, which give some mineral waters a chalky taste. Scientifically put, the Total Dissolved Solids in Vedica Natural Mountain Water is225mg/ltr. It is also high in sulphates, the natural detoxifying agents. Ensuring that all you get with Vedica Natural Mountain Water is the sweet taste of purity. Bisleri new Vedica is the most alkaline water there is. Vedica pH is 7.7, Himalayan pH is 7.3 & Evian pH is 7.2. The benefits of the alkaline lifestyle, alkaline water helps to neutralize acids and remove toxins from the body - it is a great cleanser and helps to detoxify our system. Comparative study of Chemical Parameters of Vedica, Himalayan, Evian and Volvic SR. NO. 1 2 3 4 5 6 7 8 PARAMETER PH TDS at 180 deg.C (ppm) Calcium (ppm) Chlorides (ppm) Bicarbonates (ppm) Sulphate (ppm) Magnesium (ppm) Sodium (ppm) BISLERI VEDICA 7.7 225 47 13 201 19 13 14 HIMALYAN 7.3 330 62 8 63 _ 15 20 EVIAN 7.2 309 78 4.5 357 10 24 5

Table 1: Comparative study of Chemical Parameters Source: www.Bisleri.com

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Project Report on Industrial Visit for Bisleri PLANT LAYOUT

Samant Road Dispatching Vehicles Space

Main Entrance

Security Administration Office Cabin

Western Express Highway

Laboratory Garden Blowing Wing

Stocking and Storage of the Finished Products

Disinfection of the 20 Liters Jars

i.e., 500ml, 1Litre, 20 Liters Bottles

Filling Wing

Capping Wing

Bore well

Water Treatment Plant

FIG 1: PLANT LAYOUT

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Project Report on Industrial Visit for Bisleri 2. Manufacturing Process INPUT

Raw material Without materials there can be no output. Material input may account for as much as 80% of the value of the output. This fact indicates the importance to be attached to material purchasing. The main input for Bisleri is the raw water, the raw water is obtained from the 8 bore well which are situated in the plant. The other materials required for the making of plastic bottles are polymer such as HDPE, LLDPE, PET, Recycled PET granules. Cartoons and Stickers are also required for the packing and labeling of the bottle. HPDE (High-density polyethylene) High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a polyethylene thermoplastic made from petroleum. It takes 1.75 kilograms of petroleum (in terms of energy and raw materials) to make one kilogram of HDPE. HDPE is commonly recycled, and has the number "2" as its recycling symbol. HDPE contains the chemical elements carbon and hydrogen. LLDPE (Linear low-density polyethylene) Linear low-density polyethylene (LLDPE) is a substantially linear polymer (polyethylene), with significant numbers of short branches, commonly made by copolymerization of ethylene with longer-chain olefins. Linear low-density polyethylene differs structurally from conventional low-density polyethylene because of the absence of long chain branching. It has good resistance to chemicals and to ultraviolet radiation. It has good electrical properties. PET (Polyethylene terephthalate) Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonly abbreviated PET, PETE, or the obsolete PETP or PET-P, is a thermoplastic polymer resin of the polyester family and is used in synthetic fibers; beverage, food and other liquid containers; thermoforming applications; and engineering resins often in combination with glass fiber.

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Project Report on Industrial Visit for Bisleri

Man Bisleri requires mostly skilled and semi skilled labourers. The skilled labourers include production and plastic engineers. Machine Injection moulding machine: Injection moulding machines for the production of pre-forms and caps.

Blowing machines The Blowing machines for the production of bottles from the pre-form.

Automatic fillers For the purpose cleaning and efficient filling of the bottles with least amount of rejection.

Assembly line Assembly line is used for the checking and removing the rejected bottles or damage bottles
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Project Report on Industrial Visit for Bisleri PROCESS

1. Water treatment process: Every drop of Bisleri water is purified as per international standards to ensure that Bisleri experience always remains pure and satisfying for longer. The following is a brief understanding of the water treatment process: GROUND WATER OZONISATION PRE-FILTRATION

ADDED MINERALS

MICRON FILTRATION

REVERSE OSMOSIS

FINAL OZONISATIONN

FINAL PRODUCT

FIG 2: Water treatment process diagram

I.

Ground water: The Raw water is the Water taken from the 8 bore wells present at the Plant.

II. III.

Ozonisation: Ensures water remains bacteria free for longer life. Pre-filtration: After ozonisation water goes through the Sand Filter where the solid wastes are removed. The Carbon Filter removes residual chlorine & odours.The Ultraviolet chamber helps to cure the bacteria and viruses present in water.

IV.

Reverse osmosis:

Reverse osmosis is similar to the membrane filtration treatment

process RO (Reverse Osmosis), however involves a diffusive mechanism so that separation efficiency is dependent on influent solute concentration, pressure and water flux rate .It works by using pressure to force a solution through a membrane, retaining the
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Project Report on Industrial Visit for Bisleri

solute on one side and allowing the pure solvent to pass to the other side. This is the reverse of the normal osmosis process, which is the natural movement of solvent from an area of low solute concentration, through a membrane, to an area of high solute concentration when no external pressure is applied. Reverse osmosis removes organic material. Controls total dissolved solids in the water. V. VI. Micron filtration: additional safety measures to guarantee purity. Added minerals: after the micron filtration the minerals such as magnesium sulphate and potassium bicarbonate are added in to the water, which are essential minerals for healthy living. VII. Final ozonisation: final Ozonization is a process where in Ozone gas is passed through water. It ensures water remains bacteria free for longer life. 2. Blowing In the blowing department the performs, obtained from the preforms department are blown to form bottles. There are a total of 2 fully automatic blowing machines which are directly connected to the filler. The performs are blown at 95C temperature. In one minute 65 bottles are blown.

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Project Report on Industrial Visit for Bisleri

Pre-forms are available in various sizes according to the size of bottle: Bottle Sizes 1 ltr 500 ml 250 ml 1.5 ltr 2 ltr 5 ltr 20 ltr Preform Sizes 21gms 17gms 15gms 32 gms 34 gms 75 gms 710 gms

Table no 2. Pre-form Size

3. Filling The filling department is situated in a closed and a controlled environment to maintain the hygiene. Bottles are fed by an air conveyor from the blowing unit directly into the in-feed of the RFC. RFC equipment is neck run and it boasts of a mono block unit, which means that every bottle is held by the neck automatically while being inverted, rinsed and sprayed with ozonated water at 2 Bar pressure. After draining, the bottles are re-inverted and transferred to the filler. At the filler these bottles are straightened up and gradually lifted to the filling valves which open only when a bottle is placed under them. Filling is then done systematically through gravity. The bottles are directly loaded onto the conveyor belt, first the bottles are passed through UV light to kill the bacteria, then the bottles are cleaned by pure water, then the bottles are filled to the desired quantity. The water dispenser fills the bottle till the desired level of water is filled which is checked by a sensor.

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Project Report on Industrial Visit for Bisleri

4. Capping The bottles are passed to the capper from the filler through the conveyer belt. The caps are produced in the cap department. HDPE and LLDPE which are in the form of granules are emptied into the hopper of the injection moulding machine with a colorant and the caps are produced of the characteristic green colour of Bisleri. The caps that are produced are automatically packed into cartons. This semi finished product is transported, after quality testing has been done, to the filling department. The bottles are passed to the capper from the filler through the conveyer belt. Here ozonated-water rinsed caps are screwed on the bottle with uniform torque. Since the water is ozonated all product contact parts are of 316L grade stainless steel and the rubber parts are of EPDM. 5. Labeling From the capping section the bottles are directly sent to the labeling section. All Bisleri bottles are labeled on a hot melt reel feed BOPP labeling machine. This machine allows each individual bottles to be spaced out and fed to the labeling station where precisely cut labels with a strip of hot melt glue at the leading and trailing edge, get rolled around the bottle. These labels are fed into the machine in a roll form too. 6. Coding The labeled bottles are then passed to the coder. The sensor first senses the bottle and then the price, manufacturing date, batch number are printed by spraying machine on the bottle itself, then the bottles pass through a screen of white light where workers manually check all the bottles for any defects. The code exactly contains Date, Time and Quality Checkers initials. 7. Packaging Lastly they are packed in cartons and stored in the warehouse ready for transportation to its destination. All the waste bottles are separated send to the recycling department for recycling where they are cleaned, grinded to a coarse powder which is again used in the manufacturing process, thus reducing wastages and being environmentally friendly.
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Project Report on Industrial Visit for Bisleri Outputs

The final output of whole manufacturing process is we get clean pure drinking water in Bisleri bottles of different sizes according to the needs of the consumers.

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Project Report on Industrial Visit for Bisleri

3. OBSERVATION / SUGGESSITION Bisleri has adopted many automated techniques. Examples: Conveyor belt, Blowing machines, Injection moulding machine, Automatic fillers, Assembly line. Mass Production: Bisleri produce the product in large quantity. But the production for every day is not same they produce according to the order of the suppliers or distributers. Bisleri is an ISO: 14000 certified company. The machines are placed in such a way that there is enough place for moving and relocation of the machines. Workers in the plant are required to wear head masks to avoid contamination of the product. The Canteen for the workers is conveniently located and provides hygienic food. The Washrooms for men and women workers are also conveniently located are kept in hygienic conditions.

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Project Report on Industrial Visit for Bisleri

4. Opinion about Industrial Visit

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