Trainning report pepsico_![1]

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IN-PLANT INDUSTRIAL
TRAINING
IN
PEPSICO
JUNE 10, 2019 – July 10, 2019
VARUN BEVERAGES PVT. LTD.
Varun Beverages Limited, Plot No: A-7, B-11A, C-31, Industrial Growth Centre, Defence Road,
Pathankot-145023, Punjab, India, CDV-7467

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A PROJECT REPORT SUBMITTED IN PARTIAL FULLFILLMENT OF
B. Tech Food Technology
Food Processing Department
SUBMITTED TO:
MR. LALIT PRASHAR (DGM QUALITY) MR. SATISH (DGM QUALITY)
SUBMITTED BY:
RAHUL SRIVASTAVA

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Contents
Article I. INTRODUCTION__________________________ ________5
Article II. Company History ___________________________________7
Article III.Products Profile ____________________________________9
Article IV.Raw Material/Packaging Material _____________________12
Section 4.01Raw materials: _________________________________12
Section 4.02Packaging Materials:_____________________________12
(a) Different Parameters for Quality Control of RM/PM ________12
(i) Preform ______________________________________________12
Article V. Aquafina _________________________________________22
Article VI.Quality Control Parameters :( Aquafina Bottled Water) ____24
Article VII.Can line _________________________________________27
Article VIII.Quality Control Parameters in Cans: __________________29
Article IX.Carbonated Soft Drink (CSD PET Bottles Line) __________35
Article X. Quality Control Parameters for PET Bottles _____________48
Article XI.Aseptic line beverage blending________________________55
Article XIII.Good Manufacturing Practices (GMP)_________________57
Article XIV.Good House Keeping Practices (GHK) ________________58
Article XV.CLEANING IN PLACE (CIP) _______________________59
Article XVI.EFFLUENT TREATMENT PLANT (ETP) ____________60
Section 16.01CHECKING PARAMETERS: ____________________60
Article XVII.Conclusion _____________________________________62
Article XVIII.References: ____________________________________63

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Article I. INTRODUCTION__________________________
Varun Beverages Limited is the second largest
franchisee in the world (outside US) of
carbonated soft drinks (“CSDs”) and non-
carbonated beverages (“NCBs”) sold under
trademarks owned by PepsiCo and a key
player in the beverage industry. They produce
and distribute a wide range of CSDs, as well as
a large selection of NCBs, including packaged
drinking water. PepsiCo CSD brands sold by
them include Pepsi, Diet Pepsi, Seven-Up,
Mirinda Orange, Mirinda Lemon, Mountain Dew, Seven-Up Nimbooz Masala Soda,
Evervess Soda, Duke’s Soda and Sting. PepsiCo NCB brands sold by them include Tropicana
(100%, Essentials & Delight), Tropicana Slice, Tropicana Fritz, Seven-Up Nimbooz,
Gatorade and Quaker Oat Milk as well as packaged drinking water under the brand Aquafina.
In addition, we have also been
granted the franchise for Ole brand
of PepsiCo products in Sri Lanka.
They have been associated with
PepsiCo since the 1990s and have
over two and half decades
consolidated their business
association with PepsiCo,
increasing the number of PepsiCo
licensed territories and sub-territories covered by them, producing and distributing a wider
range of PepsiCo beverages, introducing various SKUs in their portfolio, and expanding
their distribution network. They have been granted franchisees for various PepsiCo products
spread across 27 States and 7 Union Territories (except Jammu & Kashmir and Andhra
Pradesh) in India.
Their share of PepsiCo beverages volume
sales increased from ~ 26% in Fiscal 2011
to 80%+ now. Although, India is their
largest market, they have also been
granted the franchise for various PepsiCo
products for the territories of Nepal, Sri
Lanka, Morocco, Zambia and Zimbabwe.

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VBL has 30 manufacturing plants in India (Gr. Noida 1, Gr. Noida 2, Kosi, Sathariya 1,
Sathariya 2, Bazpur, Jaunpur & Hardoi in Uttar Pradesh, Bhiwadi & Jodhpur in Rajasthan,
Nuh & Panipat in Haryana, Phillaur and Pathankot in Punjab, Kolkata in West Bengal,
Guwahati Unit 1 & 2 in Assam, Goa, Mandideep in Madhya Pradesh, Bargarh & Cuttack in
Odisha, Jamshedpur in Jharkhand, Bharuch in Gujarat, Mahul, Roha and Paithan in
Maharashtra, Nelamangala in Karnataka, Palakkad in Kerala, Sri City in Andhra Pradesh,
Sangareddy in Telangana and Mamandur in Tamil Nadu) and 6 manufacturing plants in
international geographies (two in Nepal and one each in Sri Lanka, Morocco, Zambia and
Zimbabwe). In addition, they have set up backward integration facilities for production of
preforms, crowns, corrugated boxes, plastic crates and shrink-wrap films in certain of their
production facilities to ensure operational efficiencies and quality standards.
VBL is a part of the RJ Corp group, a
diversified business conglomerate with interests
in beverages, quick-service restaurants, dairy
and healthcare. Their Promoter and Chairman
Mr. Ravi Kant Jaipuria has an established
reputation as an entrepreneur and business
leader and is the only Indian to receive
PepsiCo’s International Bottler of the Year
award, which was awarded in 1997.

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Article II. Company History
The Company was incorporated as Varun Beverages Limited on June 16, 1995 at New Delhi as a
public limited company under the Companies Act, 1956. the Company obtained a certificate of
commencement of business on July 4, 1995. We have been associated with PepsiCo since the 1990s
and have over two and half decades consolidated the business association with PepsiCo, increasing
the number of licensed territories and sub-territories covered by us, producing and distributing a wider
range of PepsiCo beverages, introducing various SKUs in the portfolio, and expanding the distribution
network. As of the date of this Red Herring Prospectus, the Company has 53 Equity Shareholders.
Major events and milestones of the Company:
The table below sets forth the key events in the history of the Company:
1995-Incorporation of the Company as public limited company
1996-Started operation at Jaipur
1999-Started operations in Alwar, Jodhpur and Kosi
2004-Merger of DBL with the Company pursuant to the order of High Court of Delhi dated October
6, 2004
2012-Merger of VBL with the Company pursuant to the order of High Court of Delhi dated March 12,
2013
2013-The Company acquired the business of manufacturing and marketing of soft drink beverages
and syrup mix in Delhi, India
2015-Business transfer agreement through which the Company acquired PepsiCo India’s business of
manufacturing, marketing, selling and distributing soft drink beverages and syrup mix in the Indian
states of Uttar Pradesh (excluding certain territories), Uttarakhand, Himachal Pradesh, Haryana
(excluding certain territories) and the Union Territory of Chandigarh
-Business transfer agreement through which the Company acquired PepsiCo India’s business of
manufacturing, marketing, selling and distributing soft drink beverages and syrup mix in Bazpur,
Jaunpur, Satharia and Panipat
-The Company acquired the business of selling and distribution of soft drinks beverages and syrup
mix in one district undertaking situated in Punjab
2016-The Company acquired entire shareholding of Arctic International Private Limited in Varun
Beverages Mozambique, Limited.
-The Company acquired entire shareholding of Arctic International Private Limited in Varun
Beverages (Zambia) Limited
-Incorporation of Varun Beverages (Zimbabwe) (Private) Limited
-Acquisition of 85% of the shareholding of VBZPL
Awards and certifications received by the Company:

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The table below sets forth the key awards and certifications received by the Company:
2009-The Company received BU Best Quality Plant Team Award for the production facility at Kosi.
2010-The Company received PepsiCo Amea Bronze Food Safety Award for the production facility at
Greater Noida I.
-The Company received ISO 14001: 2004 certificate for the production facility at Jaunpur.
2011 -The Company received PepsiCo Amea Silver Food Safety Award for the production facility at
Greater Noida I. -The Company received PepsiCo Quality Excellence Bronze Award for the
production facility at Kosi. -The Company received ISO 14001:2004 certificate for the production
facility at Bhiwadi.
2012 -The Company received PepsiCo Amea Gold Food Safety Award for the production facility at
Greater Noida I. -The Company received ISO 14001:2004 certificate for the production facility at
Kolkata.
2013 -The Company received FSSC 22000:2010 certificate for the production facility at Greater
Noida I.
2014 -The Company received OHSAS 18001:2007 certificate for the production facility at Nuh. -The
Company received ISO 14001: 2004 certificate for the production facility at Nuh. -The Company
received CII National Award for Food Safety for the production facility at Nuh.
2015-The Company received FSSC 22000 certificate for the production facilities at Goa, Greater
Noida II and Kolkata. -The Company received ISO 14001:2004, OHSAS 18001:2007 and ISO
9001:2008 certificates for the backward integration facility at Alwar. -The Company received ISO
22000:2005 and ISO 9001:2008 certificates for the backward integration facility at Jaipur. -The
Company received AIB International certificate for the production facilities at Bhiwadi, Goa, Jaunpur,
Bazpur, Greater Noida II, Kolkata, Satharia, Kosi and Greater Noida I
2016 -Varun Beverages are listed and admitted to dealings on the Exchange in the list of 'B' Group
Securities

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Article III. Products Profile
Mirinda Orange
Mountain Dew
Pepsi Cola
Mirinda Orange
Aluminium Can
35 Rs/_
Mirinda Orange PET
bottle 20 Rs/-
Mirinda Orange PET
bottle 35 Rs/-
Mirinda Orange PET
bottle 56 Rs/-
Mirinda Orange PET
bottle 85 Rs/-
Mountain Dew Cans 35 Rs/-
Mountain Dew PET
Bottle 20 Rs/-
Mountain Dew PET
Bottle 35 Rs/-
Mountain Dew PET
Bottle 65 Rs/-
Mountain Dew PET
Bottle 85 Rs/-
Pepsi Cola Can Diet Pepsi Cola Zero Sugar Pepsi
Rs 35/- Can Rs30/- Cola Can Rs35/-
Pepsi Cola PET
Bottle 250 ml
Rs 20/-
Pepsi Cola PET Bottle
1.25ltr Rs 60/-
Pepsi Cola PET Bottle
2.25 litre Rs 85/-

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7UP Masala Soda
Sting
Aquafina
7UP Clear Lemon PET
Bottle 1.25 LTR Rs
60/-
7UP Clear Lemon PET
Bottle 2.25 LTR Rs 85/-
7UP Clear Lemon PET
Bottle 600 ml Rs
35/-
7UP Nimbooz PET Bottle
250 ml Rs 20/-
7UP Clear Lemon Can 250
ml Rs 35/-
Sting Energy Drink
Can 300 ml Rs 50/-
Sting Energy Drink
PET Bottle Rs 50/-
Sting Energy Drink
PET Bottle Rs 80/-
Aquafina 300 ml
PET Bottle Rs 5/-
Aquafina 1 LTR
PET Bottle Rs 20/-
Aquafina 2 LTR
PET Bottle Rs 33/-

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Tropicana
Tropicana Tetra Pak
Guava Delight 1 LTR
Tropicana Tetra Pak
Mixed Fruit Delight 1 LTR
Tropicana Tetra Pak
Pomegranate Delight 1 LTR
Tropicana Tetra Pak
100% Orange Juice 1 LTR
Tropicana Tetra Pak
100% Apple Juice 1 LTR
Tropicana Tetra Pak
Mango Delight 1 LTR
Tropicana Tetra Pak
Litchi Delight 1 LTR

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Article IV. Raw Material/Packaging Material
Section 4.01 Raw materials:
1. Co2
2. Sugar
3. Pulp
4. Water
Section 4.02 Packaging Materials:
1. Carton Insertion Pad/ Carton/ WAC
2. Preforms
3. Closures
4. Can
5. Can lid
6. Tetra laminate
7. Tetra straw
8. Tetra heli-cap
9. Label
10. Shrink film/stretch film
(a) Different Parameters for Quality Control of RM/PM
Packaging materials
(i) Preform:
 Weight
 Body diameter from lip
 Body diameter from gate
 Height
 Defects
(ii) Closure:
 Weight
 Height
 Diameter ‘outer’
 Defects
 Liner
(iii) Can:
 Empty Can- Printed Information, Appearance/Artwork
 Weight
 Height
 Brim-full Capacity; {[(weight of can + water)-weight of can]/density of water at 20o
C}

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(iv) Can lid:
 Weight
 Counter sink depth
(v) Laminate:
 GSM (Gram Square Meter)
 Repeat length
 Artwork/Printed Information
(vi) Straw:
 Weight without film
 Diameter outer
 Length A(long)
 Length B(short)
(vii) Heli cap:
(viii) Label:
 Artwork
 GSM
 Length/Breadth
(ix) Shrink Film/Stretch film:
 Thickness
 GSM
(x) Carton/Insertion Pad/WAC:
 Moisture%
 B.S./Compression Test
 GSM
 Dimension
 Flute
Raw materials
(xi) Carbon di oxide:
 Purity- 99.9% minimum
 AOT (Appearance, Odour, Taste)
(xii) Sugar:
 Colour/Turbidity- 50o
Brix
 Conductivity Ash%- 28o
Brix
 Beverage Flocculation- 54.5o
Brix
(xiii) Pulp:
 AOT
 Brix
 %Acidity
 pH

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(xiv) Water
 Iron
 Manganese
 Cl2
 pH
 Turbidity
 O.R.P.
 T.D.S.
 Conductivity
 S.D.I.
 Ozone
Raw Material Testing:
CO2 testing
~ CO2 Purity testing
Objective/Purpose: The purpose of this test is to provide a rapid measurement of the overall carbon
dioxide purity.
Equipment & Reagents:
 Sodium or potassium hydroxide solution, 10% strength
 Zahm & Nagel CO2 Purity Tester.
 18” length of 1/4” or ¾” rubber or plastic tubing ¼” or 3/8” in-line CO2 sampling valve
(downstream of CO2 vaporizer; must be regulated to below 10 psi prior to attaching
apparatus).
Procedure:
1. CO2 purity tester is attached to gas sampling valve.
2. CO2 is purged through empty apparatus, then collected in calibrated bulb section.
3. Reservoir portion of apparatus is filled to mark with hydroxide solution.
4. Hydroxide is allowed to equilibrate with sample, and the CO2 is absorbed by the caustic,
other gases are not absorbed.
5. Per cent purity above 99.0% is read directly from the graduations on the measuring
portion of the apparatus.
Tips & precautions:
1. Follow all the necessary safety precautions when sampling and handling CO2, and when
handling sodium/potassium hydroxide solution e.g. wearing protective gloves and safety
glasses.
2. CO2 pressure should be below 10 psi prior to attaching the apparatus for sampling.
3. Be sure to purge CO2 prior to closing valve to obtain sample.
4. Hydroxide solution (sodium/potassium) should be changed after 5 tests.

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Zahm & Nagel CO2 Purity Tester
Principle:
CO2 Purity Kit (Zahm-Nagel) measures the percent purity of CO2 by caustic absorption of a fixed volume
of gas (ex. ISBT Method 2.0). This is done by a precise volume measurement of total "caustic insoluble"
gas impurities trapped as a 'bubble' within a percent purity scaled burette.
~CO2 Testing (TOA)
Materials Required:
 Protective safety gloves
 Forceps
 Two 250 ml beakers
 Plastic “Whirl-Pak” bags or equivalent.
 Reagent- Cold distilled or treated water.
 Pressure regulator
 Safe source of CO2 with sampling port.

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Procedure:
 Collect CO2 sample in whirl-pack bags.
 Evaluate odour of gas.
 Place CO2 “Chunk” in beaker of water.
 Swirl to mix and bring to room temperature.
 Pour into sample cups.
 Evaluate odour of sample.
 If odourless, then stop and don’t taste it.
 If odour is determined then, evaluate the taste.
Tips & Precautions:
 Liquid CO2 has a temperature of -40 degree Fahrenheit. It will cause severe “burns” to the
skin if handled improperly. Vaporized CO2 can also damage skin.
 Protective gloves should always be used when handling CO2.
 If CO2 does contact skin, keep the exposed area warm and contact a physician if necessary.
Sugar Testing
~Sugar A.O.T.
Objective: To check appearance, odour, taste of incoming sugar, to identify any gross contamination.
Requirements/Equipment:
1. Odourless 2 litre PET or equivalent jar with lid.
2. Clean 150 mm Petri plate.
3. Clean 250 ml glass beaker.
4. Spatula.
5. Sensory cup.
Procedure:
Appearance & Colour of sugar-
1. Weigh 10gm of sugar in clean odourless beaker.
2. Add 90 ml treated water in the beaker having sugar sample.
3. Add 35 ml phosphoric acid in the beaker.
4. Dissolve the sugar by magnetic agitation.
5. Check the appearance in the white light (sugar should be free of foreign material).
6. Swirl the liquid and check the odour of the liquid (No off odours should be present).
7. Now check the taste of the liquid (taste should be sweet with no presence of abnormal
flavours).
Jar Odour Test:
1. A clean and odourless PET jar/bottle was taken.
2. Half of the jar was filled with sugar sample.
3. Container was closed with air tight lid.
4. Jar was shaken slightly.
5. Closure was removed and the bottle was squeezed to release gases.
6. Odour was evaluated as either cane sugar or beet sugar as follows:

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Cane Sugar: Should have a cane molasses, caramel like odour or little to no odour.
Beet Sugar: Should have an earthy, pungent, amine like (bet amine) odour.
~Sugar (Ash & Conductivity Test)
Objective: To measure organic and inorganic salts in sugar, this is one of the primary indicators of
sugar sensory performance.
 250 ml glass beaker
 Magnetic stirrer
 Electronic balance
 Deionized water/Distilled water
 Conductivity meter
Procedure:
1. sCollect the sugar sample in clean dry beaker.
2. Weight 28.0 gm sugar in another beaker.
3. Add 72 gm deionized/distilled water in it.
4. Dissolve the sugar by stirring on magnetic stirrer.
5. Place the calibrated conductivity meter bulb in the solution at 20 0.5
6. Record the results.
Note: For Ash% use the below given formula for calculation.
Ash% =
Significance:
Simple and rapid methods are needed for the determination of purity of sugar products that may
contain electrolytes and non-sugars. Using conductometric studies of cane juice and cane sugar
systems shows that the conductivity is linear with the electrolytes and non-sugar present in both cane
juice of 20% v/v as well as in cane sugar over the range of 0 to 20 % w/v. With present method
linearity can be approached more nearly by increasing non sugars concentration, but a parallel
decrease in sucrose purity. Another observation comes out from acidity measurement of cane juice
increases 0.1%, whereas, increase in conductivity value is around 11%, indicating conductivity is
more informative, precise, and controlling parameter than conventional acidity parameter.
Encouraging results have been obtained in the determination of non-sugars and electrolytes part in
sugar products. Percent reflectance values of sugar were also taken and compare with conductivity
data for quality assurance of cane sugar.

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~Sugar (Colour & Turbidity Test)
Objective: To determine the Colour and turbidity of the sugar sample.
 2 - 500 ml glass beakers
 Vacuum filtration setup
 0.45µ filter paper
 Weighing balance
 Hot Plate Magnetic Stirrer
Procedure:
1. Take 100 gram sugar sample in a clean dry beaker and makeup to 200 grams by adding
distilled water.
2. Put the bar magnet in the beaker and keep the beaker on hot plate magnetic stirrer, and start
the mixing by magnetic stirrer.
3. Filter out the prepared sugar syrup using 0.45 Filter paper and the vacuum filtration setup.
4. Fill the spectrophotometer cuvette with distilled water and zero out the colour units in
ICUMSA units.
5. Wash the cuvette and wipe it dry with tissue papers, now fill with filtered sugar syrup (50
Brix).
6. Observe the colour reading using the single beam spectrophotometer, then zero out the
turbidity using the same filtered solution.
7. Now wash the cuvette and wipe it dry using tissue paper, then fill the unfiltered solution into
the cuvette and observe the turbidity readings.
o Principle: A magnetic stirrer is a laboratory device consisting of either a rotating magnet or
stationary electromagnets creating a rotating magnetic field. This device is used to cause a stir
bar immersed in a liquid to spin very quickly, agitating or mixing the liquid. A magnetic
stirrer often includes a provision for heating the liquid.
o Principle: Spectrophotometry deals with visible light, near UV and near IR. To acquire the
spectral information quicker in IR spectrophotometers, which use a Fourier transform
technique and is called Fourier transform infrared (FTIR).
Hot plate magnetic stirrer
Single beam spectrophotometer

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Pulp Testing
~pH Testing
Objective: To determine the pH of the given fruit pulp.
Requirement/Equipment:
 500 ml Beaker
 Digital pH meter
 Distilled water
 Measuring cylinder
 Tissue paper
Procedure:
1. Weigh 10 gm pulp sample in beaker on weighing balance.
2. Makeup 40 gm weight with distilled water.
3. Wash the pH probe with distilled water and wipe dry with tissue paper.
4. Dip the magnet in the beaker containing pulp sample and then dip the pH probe in the sample,
start the measurement.
5. Record the observations &clean all the apparatus with distilled water and wipe dry with tissue
paper.
~Percent Acidity
Objective: To determine the per cent titerable acidity of pulp.
 250 ml Beaker
 Digital pH meter cum auto – titrater.
 Distilled water
 Tissue paper
Procedure:
1. Weigh 10 gm pulp sample on weighing balance, makeup to 40 gm with distilled water.
2. Dip the bar magnet in the beaker, and the probe in the beaker containing sample.
3. Enter the sample size in the auto titrater.
4. Start the titration with 0.1 N NaOH and titrate to 8.35 pH.
5. Observe the calculation and then clean the apparatus with distilled water and wipe dry the
apparatus with tissue paper.

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Water Testing
~Silt Density Index (SDI)
Objective: To estimate the amount of particulate contamination in water.
 Membrane filter discs, 0.45 micron, 47 mm diameter, cellulose tri-acetate (Millipore, or
equivalent)
 Pressure regulator up to 100 psi (7 bars)
 Pressure gauge up to 60 psi (4 bars)
 Filter holder
 Tweezers
 Stop watch
 500 ml glass beaker
Procedure:
1. Flush the sampling line for 3 to 5 minutes before installing the test apparatus.
2. Connect the SDI apparatus, without the membrane filter, to the sampling line.
3. Open the valve on the test apparatus and flush the apparatus for 2 minutes with the water to be
tested.
4. Set the pressure regulator to 30 psi (2 bars). Then set screw on the regulator should be adjusted
while there is a low flow.
5. Close the valve on the apparatus and release the pressure.
6. Using the tweezers, place a 0.45 micron Millipore filter in the filter holder with the shiny side
up and gently tighten the Millipore holder bolts.
7. Partially open the valve, and while water is flowing through the test apparatus, carefully loosen
two of the holder bolts and tilt the holder to be sure that all of the air has been vented from the
filter holder.
8. Close valve and tighten Millipore filter holder bolts.
9. Place the discharge line of the filter into the granulated cylinder or beaker.
10. Open valve fully and with a stopwatch, immediately measure the time required to collect 500
ml of filtrate in a beaker (record as time).
11. Continue the flow of feed water at 30 psi for a full 15 minutes.
12. Again, record the time required to collect a second 500 ml sample (after 15 minutes of flowing).
Record this number as Tf.
Calculations
Where,
SDI = Silt Density Index
Ti = initial time, to collect 500 ml water
Tf = final time to collect 500 ml water after 15 minutes of flowing
General formula:
SDI = (% plug gage)
SDI = ⁄
SDI = Silt Density Index

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Ti = initial time to collect 500 ml
Tf = final time to collect 500 ml after 15 minutes of flowing.

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Article V. Aquafina
(500, 1000, 2000 ml bottles)
R.O. treated water from
G2G tank
R.O. Membrane 1, 2
Ozone Contact Tank
Permeate Permeate Permeate
Drainage
R.O. Membrane 3
Pump Supply for
Aquafina
Micron Cartage (5µ),
30``
High pressure pump
Reject Reject
R.O. Membrane 4
Aquafina Treated
Water
To Aquafina bottle production
line

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Aquafina Bottle Production Line
Preform Dumping Station
Preform alignment
Dust Collection
by industrial dust
collector
Guide
rail for
mould
opening
Preform
fetch/discharge
transmission tray Blow Moulding @40 bar pressure
Mini
Hopper
Bottle chilling/rinsing by 10-13°C
Water
Closure Feeding Hopper
Preform Feeding in Automatic
Rotary Blow Moulding
Machine
Closure Vibratory
Alienation
Closure feeding guiderail
Empty
Moulded bottle
Filling Capping Machine
Aquafina treated
water
Nitrogen Storage Tank
Bottle Guiderail
Closure Check point
Air drying before labelling
Bottle labels checking by
DPX1000
Automatic Shrink-Wrapper
machine
Stretch wrapped in palletizer
unit
Warehouse/Storage

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Article VI. Quality Control Parameters :( Aquafina Bottled
Water)
o pH
o Turbidity
o Conductivity
o Total Dissolvable Solids (T.D.S)
o Organic Residue Particles (O.R.P.)
o Iron
o Manganese
o Cl2
o Silt Density Index (S.D.I.)
Objective: Measuring the pH of water.
Apparatus:
o Beaker 250 ml
o Tissue paper
o pH meter
o Distilled water
Procedure:
1. Wash the probe of pH meter using distilled water.
2. Wipe dry the probe of pH meter using tissue paper.
3. Put the beaker with sample water on the magnetic stirrer plate with magnet inside the beaker.
4. Put the pH probe inside the beaker.
5. Start the pH measurement, record the observations.

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Objective: Measuring the turbidity of water.
Apparatus:
o Turbidity meter
o Tissue paper
o Sampling vial
Procedure:
1. Wash the sampling vial with distilled water.
2. Wipe dry the sampling probe with tissue paper.
3. Fill the vial with sample water and wipe clean the vial from any kind of dirt, dust or any
fingerprint.
4. Put the sampling vial in the turbidity meter.
5. Start the measurement and record the observations.
Test Significance/Principle:
Turbidity affects the growth rate of algae (micro-aquatic
plants) and other aquatic plants in streams and lakes because
increased turbidity causes a decrease in the amount of light
for photosynthesis. Turbidity can also
increase water temperature because suspended particles
absorb more heat.
Objective: Measuring the conductivity and T.D.S. of water.
Apparatus:
o Conductivity meter
o Tissue paper
o Beaker 250ml
o Distilled water
Procedure:
1. Wash the probe of conductivity meter with distilled water.
2. Wipe dry the probe of conductivity meter with tissue paper.
3. Dip the probe in beaker containing distilled water.
4. Start the measurement of conductivity meter, record the observations.

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5. Repeat steps 1 & 2 and then dip the probe in beaker containing sample.
6. Start the measurement and record the observations.
Significance:
Conductivity is a measure of the ability of water to
pass an electrical current. Because dissolved salts
and other inorganic chemicals conduct electrical
current, conductivity increases as salinity
increases. Organic compounds like oil do not
conduct electrical current very well and therefore
have a low conductivity when in water.
Conductivity is also affected by temperature: the
warmer the water, the higher the conductivity.
~ORP Test
ORP sensors work by measuring the dissolved oxygen. More contaminants in the water result in less
dissolved oxygen because the organics are consuming the oxygen and therefore, the lower the ORP
level. The higher the ORP level, the more ability the water has to destroy foreign contaminants such
as microbes, or carbon based contaminants.
ORP level can also be viewed as the level of bacterial activity of
the water because a direct link occurs between ORP level and
Coliform count in water.
Note:
Other water testing parameters like Iron, Chlorine, ozone and Chloride etc. are done using the
given techniques and their determined measurement kits.

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Article VII. Can line
250 ml size:
Products: Diet Pepsi, Pepsi, Mirinda, Mountain Dew, 7up etc.
Empty Drawn Can Receiving
DE palletizing in empty pack
Depalletizer Machine
Can Ovality and diameter check
Jet spray empty can rinse at 1 bar
pressure
Counter filling of cans at 4 bar pressure
Pressurized counter seaming of cans
Fluid level and net content checking and
rejection station
Can inversion
Cans Conveyed to warmer
through holdup chain conveyor
Warming of cans from 4-6 to 20-
25 to prevent Dew Point in cans
during stacking in cartons.
Secondary drying to facilitate
Laser coding at the bottom
of cans at 40-42

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Primary coding of cans like: price,
MFG date, Batch code etc.
Can diameter, coding
checking and rejection
station
Can Inversion
Chain conveyed to
vibratory arranger
Shrink wrap of cans in 2 3 stacks at 164-
165 temperature in shrink wrap machine
Cool air blowing to set
the shrink wrap
Tray packing of cans in 3 3 stacks
with shrink film
Wrap around Carton (WAC) packing of
2 stacks
0
Air blowing to cool
down the cartons
Layer by layer forming pallets, 13cartons
in 1 layer, and Total 10 layers in 1 pallet
Stretch wraps palletizing in automatic
palletizer
Warehouse storage/ Dispatch to
market

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Article VIII. Quality Control Parameters in Cans:
o Brix of the final product
o Inverted Brix of the product
o Gas volume of the final canned product
o Headspace air purity testing
o Empty can enamel conductivity testing
o Can lid conductivity testing
o Can seam level testing
o Final canned product Leak Test
o Counter sink depth of final canned product
Final Product Quality Testing:
~Brix Testing
Objective: To measure the sugar content in the final product in brix format.
 Tissue paper
 Distilled water
 Spatula
 Digital refractometer
Procedure:
1. Wash the sample tray with distilled water.
2. Zero out the refractometer with distilled water, and wipe dry with tissue paper.
3. Put the beverage sample in the sample tray using spatula.
4. Start the measurement and record the observation.
~Inverted brix
Objective: To measure the true brix or inverted brix of the final beverage product.
 Measuring cylinder
 Screw bottle
 Water bath
 0.6 N Hcl
 Digital refractometer
 Spatula
 Pipette & Pipette holder
 Distilled water
 Tissue paper
Procedure:
1. Rinse the glass screw bottle and measuring cylinder with the sample beverage solution.
2. Measure 30 ml of solution in measuring cylinder and then transfer it in the screw bottle.
3. Pipette out 0.1 ml 6 N Hcl using the pipette and pipette holder.

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4. Mix the solution with Hcl solution and screw close the bottle.
5. Put the screw bottle on the water bath for 40 5 minutes at 98 2 .
6. Cool down the hydrolysed beverage sample in refrigerator.
7. Wash and zero out the digital refractometer with distilled water and then wipe dry with tissue
paper.
8. Put the beverage sample in sample tray using a clean dry spatula.
9. Record the observations.
~Gas volume
Objective: To check the available quantity of CO2 in the beverage solution.
Requirement/ Equipment:
 Zahm & Nagel Gas volume calculator.
 Distilled water.
 Tissue paper
Procedure:
1. Warm up the PET bottle containing beverage to a temperature of 20-25 .
2. Shake the bottle 30 times in 15 seconds.
3. Put the bottle on the G.V. Calculator and tighten up the seal using pressure weight.
4. Close the gas release valve and push the rod shaped thermometer inside the bottle closure.
5. Open the valve and let the internal pressure drop down to 2 psi.
6. Close the valve again and shake the whole apparatus carefully until the pressure gauge becomes
stable.
7. Observe the pressure and temperature readings in the gauge.
8. Use the G.V. Calculator chart to get the CO2 content in the PET bottle.
Test Significance:
CO2 (carbon dioxide) is a critical ingredient in beer, soft
drinks and other beverages. The traditional method of
determining carbonation by measuring the total pressure
overestimates the amount of CO2 in the drink due to the
presence of other gases, resulting in consumers experiencing
a flat drink.

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~Headspace air piercing and purity testing:
This instrument is used to test beverage or
product for CO² gas and air content in
either glass or PET containers or cans. It
is automatically adjustable to various size
bottles and cans and is available in either
one or two liter sizes. Two standard
pressure/temperature relationship charts
are furnished with the instrument for the
determination of volumes of CO² gas in
alcoholic and non-alcoholic beverages.
The instrument is equipped with a dual
scale pressure gauge (0-60 psi and & 0-
4.2 kg/cm2) and an adjustable 2″ dual
scale dial thermometer (25.125ºF & -
5/55ºC). This piercing device is also
equipped with a 100cc burette that
measures up to 25cc’s of the product’s air
content. The parts list and line drawing
should be used for assembly and as a
reference for ordering replacement parts.
[Note: Headspace “air” is defined as
atmospheric air picked up during the
brewing process. These instruments do
not measure dissolved oxygen.]
~Can Enamel & Lid conductivity testing
Enamel, glass and ceramics are good insulators. This
property is of course especially useful in the
manufacture of electro technical porcelain and
dielectric enamels. Insulators made from electro
technical porcelain are provided with a high-gloss
glaze. This glaze has low electrical conductivity
properties and prevents the accumulation of dirt due to
its
smooth surface. Dielectric enamels do not contain
alkalis and otherwise differ in structure from
conventional enamels.

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~Can Double Seam Testing
The seam projector is a computerized accurate machine that not only displays an ex-ray-type image
on the monitor, but is also capable of precisely calculating the seam measurements.
Parameters:
 Counter sink depth
 Seam length
 Seam thickness
 End / cover hook
 Body hook
 Overlap
 Body hook butting in %

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~Final Canned Product Leak Test
Objective: To check the final canned product for any leaks.
 Water bath
 Tissue paper
Procedure:
1. Wipe clean and dry a final canned product.
2. Dip the can inside the hot water bath at 50 for 5 minutes.
3. If any leaks or bulging occurs then record the observations.
~Counter sink depth
Countersink is the critical external measure of the
double seam.
Countersink is important since it is the exact area
where chuck holds on to the end during double
seam formation. If it is incorrect, critical defects
such as DEAD HEADS and FALSE SEAM will
occur.
The beverage Countersink Gauge provides a
quick and easy way for measuring countersink
depth on beverage and beer cans.
Easy to learn and use by any operator – the gauge
is held upright on top of the can while the
measurement anvil goes down to the lowest
countersink value.
Using a 10 micron resolution gauge, the
information can be easily and automatically
transmitted to the hosting computer – to any
software package that supports it: SEAM Metal
or Symphony software.

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Countersink Depth Measurement - Prior to using the countersink gauge, ensure that the point is
tightly screwed onto the shaft. Place the bar of the gauge on a flat surface, preferably a block of
machined steel large enough to detect warps in the bar (the bar of a second countersink gauge is
useful for this purpose). In this position the point of the gauge is at the zero position and the dial of
the gauge should also read zero. To adjust the "zero" on the dial, loosen the knurled screw near the top
of the dial, rotate the outer scale until the zero and the indicator coincide, and tighten the screw to lock
the gauge at the zero position.
Rest the bar of the depth gauge on top of the seam across the top of the can as shown in Figure.
Position the point of the depth gauge pin (shaft) at the lowest point adjacent to the countersink wall
(but away from the crossover of three piece cans).

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Article IX. Carbonated Soft Drink (CSD PET Bottles Line)
CONTIFEED
Well shorted the contifeed is roller oriented provides the contiform with perfectly
oriented pet perform .the shorter is infinitely adjustable meaning it is suitable for any perform
size. Since the contifeed roller shorter is available in several length, it can be adjusted
precisely to suit the layout and output of your line. A perform tipper dumps the supplied PET
perform into the perform hopper of the perform feed system from there, an elevator conveyor
the perform without pressure to the roller shorter via intermediate conveyor , there they are
oriented by two roller running in opposite direction and the feed rail transport them to the
blow moulder . Any perform which have not been sorted are automatically rejected and
conveyed back to the dump chute
 PREFORM HOPPER
 ELEVATOR
 INTERMEDIATE CONVEYOR
 ROLLER SHORTER
 RETURN CONVEYOR
 FEED RAIL
 CONTROL CABINET
 OPERATOR PANEL

36 | P a g e
Method of operation
 Instead of using a perform hopper ,a conveyor I used as a perform buffer
 The perform are conveyed from the preform tipper to the conveyor at a low height
EFFECT
 Reduced perform drop height
 Gentle material treatment
 Reduced noise level during production
CONTIFORM
The contiform operates according to the two stage process in which PET performs are blown
to form bottle are first carried through a modular linear oven which has been heated up to its
optimum processing temperature. They are then transferred to the cam controlled blowing
wheal where nomic application of energy are used to blow mould them into bottles.
At a glance
1) Container range
 Round , oval , square and rectangular
 For noncarbonated water ,CSD and hot fill products
2) Output per hour
 up to 2500 containers per blowing station
 total of up to 81000 containers
3) Machine size
 minimum of 8 cavities
 maximum of 6 container

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PARTS OF CONTIFORM
 perform feed system
 infrared linear oven with ceramic reflectors
 torsion resistant platform
 monotec servo motors
 blowing wheel with electromagnetic stretching system
 machine guards in hygienic design
 touch screen
INFRARED LINEAR OVEN
 very small oven chain pitch
 very small heating room which can be adjusted to the respective task
 maintenance free system of ceramic reflectors
TRANSFER SYSTEM
 five point heating mandrel in the linear oven
 only four internal horizontal perform and container transfer points
 maintenance free system of ceramic reflectors
DRIVE TECHNOLOGY
 with real time five highly precise monotec servo motors
 synchronisation
 installed on a torsion –resistant platform structure
 for a trouble free and energy efficient production

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BLOWING STATION
 electromagnetic stretching system without compressed air
consumption
 attached the 14 mould
 size and shape of mould are different to the size of bottle
 moulding done into three steps
 pre moulding
 intermediate moulding
 final moulding
BASE COOLING
After the moulding base of bottle very hot so need to cool the base .this base cooling system
flow the water into the base of bottle the temperature of water range 17 to 19degree Celsius

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CONTIFLOW MIXER
 depending on your demand :
 2 component mixer (water+ syrup+ co2)
 multiple component mixer for up to 8 component
 modular and compact design
 also available as carbonation deaeration or dosing carbonation module
METHOD OF OPERATION
The contiflow consist of the modules
Deaeration:-
 water feed to the horizontal deaeration tank via two differently large sets of nozzle
 deaeration via the single stage or double stage vacuum process and optional stripping
gas
 reduction of the sealing water consumption to a minimum
Dosing
 adding the syrup with a high register control
 exact brix value control via flow meter
 dosing of up to eight liquid components possible
 top product quality due to multi stage product homogenisation
Carbonation
 high precision carbonation consistent volume flow rate in the carbonising
nozzle

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 variable mixer output from 100 to 33 percent
 dosing of up two gaseous ingredients possible
 consistent level of technologies value despite of variable output regulation
Modulfill
Volumetric filler used for filling of beverage in PET bottle. Filling of filler is umbrella filling
means beverages come into the bottle by surface .filler attached 104 filling valve and the
RPM of the filler is depended on the size of bottle.
Method of operation
First the PET container is pressed on and pressurised. The filling process will start as soon as
the same pressure prevails in the tubular ring bowl and in the PET bottle two different filling
speed guarantee optimum flow. An inductive flow meter checks the quality of inflowing
liquid. The valve closes once the exact filling volume has been reached . After a settling
phase, the pressure in the head space of the PET container is reduced via a snifting valve and
the filling product exits the machine.
Clever– two gas channels for double the hygiene
The container are pressurised and sniffed via two separates gas channels. This separation
prevents liquid from the filled container into the pressurisation channels providing
considerable advantage with regard to filling stability and hygiene.
APPLICATION
This variant of the modul fill volumetric filling system was designed especially for cold
filling of CSD beverages in combine with hot filling of juice in PET container.
It separates channels for the product return is integrated in the filling valve for the purpose.
1) control cylinder for liquid valve

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2) pressurisation and return gas valve
3) switching valve fast/slow
4) snifting valve head space
 snifting and CIP return channel
 pressurisation and CIP return channel
MODULCAP CM PLASTIC SCREW CAPPER
The krones modulcap number of CM plastic screw caps and applies them precisely on PET
bottle even at high output
FIELD OF OPERATION
 26 MM
 28 MM
 38 MM
 28 MM and 38 MM SPORTS CAPS
METHOD OF OPERATION
The screw caps are spaced an oriented in the sorter and then fed to the sealer from above the
pickup device fixes the caps in the capping head. PET bottle are held in place by spikes on
the neck star wheel disk.
The capping head applies the cap. The cap is pressed into the bottle by means of spring
pressure . At the same time it is screwed into the thread of the bottle neck finish. As soon as
the rotation is ended and the required tightening torque is applied to the cap, a hysteresis
clutch ends the capping process. This clutch enables smooth braking and a constant
tightening torque at all filler speed

42 | P a g e
CHECKMATE
It checks that the fill level in the bottle ok & is the cap position straight does the safety ring
hence it justify its name the checkmate inspection system
1. Overfill
2. Under fill
3. Cap
At a glance
 Full-container inspection unit fill level inspection unit with high frequency, infrared
camera, gamma or x-ray technology
o Cap and safety ring detection unit with sensor and camera technology

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WARMER
Cold beverages are literally too cool for their packaging .as soon as the container leave the
filler condensation collect on them the result soaked cartons and damage. This can be
prevented with the leathern warmer. It is employed right to after the filler and it gently adapts
the containers temperature to the ambient temperature .Hence, there are no obstacles to
perfect labelling and packaging.
Method of operations
Depending on a size the container will pass through four treatment zones each zone
temperature different and set the temperature of zone according to size of bottle. Spraying
nozzle shower the bottle with precisely tempered water thus the containers genteelly treated
to the ambient temp and generation of condensation water is prevented.
Output/Capacity
10000-90000 containers per hours
AIR DRYER
A compressed air dryer is used for removing water vapour from the compressed air into the
bottle compressed
The temperature of the compressed air dryer is very high so bottle spend time in the dryer is
very short

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CONTIROLL
The machine has a rotary design with a precisely operating labelling station container as far
as efficiency accuracy and speed are concerned the conti roll labeller with its permanently
developed technology leads the field
Principle of operation
A feed roller the speed of which is adapted to suit the label length continually pulls the label
web from the reel. The label wed guider which is installed as standard is responsible for
ensuring that the label web is pulled straight. In the cutting unit the labels are precisely cut
while a computer and servo motor provide an exact cut off point.
Two narrow strip of hot melt which are applied by a heated glue roller to the leading and
trailing label edges glue the label together the hot melt strip applied to the leading label edge
ensure a precise and positive transfer into the rotating container . Glue strip ensure that the
label is positioned precisely and glued correctly. As the container is rotating while the label is
being applied the label is stretched to fit smoothly. When the trailing edge is glued down the
secure bond is complete.

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PRIMARY CODING
Primary coding is done into the surface of bottle to saw the branch name, branch number, line
number time, date, year, batch number.
Primary coding is done by the laser coding principle. Laser marking is with a laser beam to
get permanent marks on a bottle of beverages
CHECKMATE
Checkmate checks the labelling of bottle and registered mark if the checkmate detects the
incorrect labelling and registered mark checkmate fall the bottle into the conveyor
DEMACK MACHINE

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Demack is a leader in the supply of continuous film and sealing bar shrink wrappers with
heat-shrink film, wrap-around cartooning machines, tray packers and combined lines. It has a
portfolio of products and services designed according to a thorough analysis of customers'
demands and opinions, translating them into highly reliable standard solutions through the
use of original and cutting-edge techniques.
SECONDARY CODING
Secondary coding is an inkjet coding. Secondary coding told about the address of industry it
also show about the company number, batch number manufacturing date, time and flavour
name, MRP
PRINCIPLE
Inkjet printing is a type of computer printing that recreates a digital image by propelling
droplet of ink into pepper plastic or other substrates

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PELETIZER ROBOT
Flexibility is one of the special features of a robot which is used for packaging and
palletising. In additional to packing and unpacking task the robogrip masters palletising task
for the single packs, rows or layers. With a large number of optional gripper or
multifunctional tools the robogrip is ready for any and everything. Its large operating range
enables the robot to access an amply dimensioned operating surface and thus ensures almost
efficiency during packing and labelling.
At a glance
 articulated arm robot with four movement axes
 output up to 550 clock pulse per hour , depending on the load bearing capacity with a
standard pivoting area of 2 * 180
 safe operation with a controller monitored safety system

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Article X. Quality Control Parameters for PET Bottles
o Filled & Empty Bottle Top Load Test
o Closure opening torque with filled bottle
o Fill height
o Net content
o Bring full
o Base crack test
o Bottle height
o Body diameter
o Bottle thickness
o Section weight
o Base clearance test
~Top load test
Top load tester – This test is performed to test
the stacking load bearing capacity of the bottle.
When stored in a warehouse, bottles are stacked
over each other. If bottles are not tested for top
load, they might develop buckling or deformity
due to overloading. If packager issues
instructions for a warehouse manager to keep the
maximum load beyond a certain limit, which is
fetched after top load testing; such failures can
be avoided. This test is equivalent to
compressive testing. Knowing buckling load will
help the packager to identify the defect in the
manufacturing line. This helps in avoiding
product failure during transit.

49 | P a g e
~Closure opening torque
Loose bottle caps can lead to both package and product issues. This can happen due to the loss of
nitrogen in non-carbonated drinks or carbon dioxide in sodas or entry of moisture molecules into a dry
product. This can result in discoloration, significant changes in taste or texture, and thereby, affect the
quality of the overall product. In order to maintain the quality, it is very important to maintain the
caps’ integrity constantly.
In earlier practice, cap torque testing was as easy as taking a bottle from the production line and
manually twisting the cap to check how tight it is. But in today’s industries, the need to acquire
accurate torque test results is rising rapidly.
The target of this testing is to eliminate the human-induced errors by providing a consistent, accurate
and repeatable testing speed that avoid additional pressure or unnecessary acceleration on a product
during the testing procedure. Thus, the results produced can be evaluated by the quality team in order
to validate and confirm that caps will be able to prevent leakage during transit and storage conditions.
The test is conducted in two steps:
 Removal of cap – In this, the test is conducted in the opening direction up to the limit the cap
begins to slip on the bottle neck. Upon detection of rotational movement by the device, a peak
removal torque will be computed and the system will stop rotating.
 Application – The closure is then re-applied to the bottle after the removal torque is
calculated.
Utilizing a motorized cap testing machine removes the human errors during cap testing. It generates
precise testing data that can be evaluated by the production team. It allows saving money by lowering
the amount of wasted packaging and product over the course of large-scale production.

50 | P a g e
~Fill Height
To measure the net volume of the pet bottles a long
rod vernier caliper is used. With its help the net
empty height is determined.
~Net Content
To measure the exact gross weight of the final packed product. It is determined using the weighing
balance.
~Bring Full Test
To test the maximum beverage holding capacity of the PET bottles they are filled to the top most
possible height and then their weight is recorded.
~Section Weight
Beverage industry invests a huge sum of money to assure the quality of the bottles. Preforms and PET
bottles both undergo a different type of testing procedures to make flawless bottles. If the quality of
the bottles is not as per the standards, it may lead to the failure of the products packed inside. This

51 | P a g e
invites negative feedback from the customers, leaving a bad impact on the brand. And this involves a
huge cost of wastage and rejection. Thus, to cut down all these, sectional weight analysis of bottles is
done using hot wire bottle cutter.
The success of a beverage industry depends a lot on its bottles. The quality of a bottle is determined
from its stability and durability. The structural analysis of the bottles sometimes becomes a tricky
task. To achieve that perfectly balancing structure, manufacturers compromise with the design and
aesthetics. But with appropriate testing, good design and quality, both can be achieved. Sectional
weight analysis tells a lot about the balancing of the bottle. While designing the structure, experts set
some weight standards for each section of
the body. If there is a disparity in the
section weight, the end result might
topple.
To estimate the quality of the bottles, the
testing procedure includes sectional
weight analysis. This is done prior to mass
production, on the sampled bottle. This is
a destructive test and sample is absolutely
useless after the testing. In this test, the
bottle is cut into 3-4 parts, depending upon
the size. Ideally, every section should have
a uniform distribution of weight. To
analyse the uniform distribution, it is
important to cut the bottle perfectly into
sections without any deformity. The shape
and size of every section should be uniform. Any deformation may lead to the inaccurate test results.
Procedure:
The temperature of wires is increased to a level where they can cut the bottles easily. The wires
attached to the frame are made to pass through the bottle by cutting them. The sections are then taken
out and weighed. The observations are matched with the internal standards defined by the experts. If
there is any disparity in the weight, the design can be reconsidered.

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~Bottle Thickness
To ensure the quality and strength of the PET bottles it is mandatory to check the uniform thickness of
the bottles.
This test determines the uneven wall thickness of the PET bottle. Due to improper thickness
distribution, the deformity easily occurs in structure. To make it fit to use in the stressful environment,
it is very important that bottle should have perfect structure.
~Body Diameter Test
Diameter of:
1. Shoulder 2. Major and 3. Base
These are measured to check the standard quality of PET bottles that they are fulfilling the FSSAI and
ISO parameters of food grade packaging bottles.
~Base Crack Test
Objective: To check the stress strength of the Pet bottles.
Requirement/ Equipment:
 Stainless steel tray
 2000 ml NaOH 10% strength.

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Procedure:
1. In a clean stainless steel tray pour the 10% strength NaOH.
2. Put the filled PET bottles in the stainless steel tray in standing position for 2 hours.
3. After every 2 hours take the observations for any type of cracks, stress, bulging or denting up to
next 8 hours.
Importance/ Significance:
It is necessary to check the stress cracking or bulging of the PET bottle bases in most adverse
conditions to prevent any kind of mishandling and bursting in the open market.
~Bottle Burst Test
In aerated drinks filling line, the bottles are filled with extreme pressure which sometimes may lead to
the bursting of the bottle. High pressure is required during filling to keep the freshness intact, but this
may lead to bursting of bottles sometimes.
Therefore, it is necessary to determine the
bursting strength of PET bottles with the help of
Bottle Burst Tester.
One common test that is performed by every
manufacturer is Bottle burst test to check the
sustainability of the bottle under extreme
pressure. Especially in aerated beverages, due to
excessive shaking, there are chances of generation
of high pressure inside the bottle. This may lead
to bursting of bottle if it doesn’t have enough
strength. With the bottle bursting test,
manufacturers are able to identify the exact
amount of pressure that a bottle can sustain.
Also, during extensive research, the design of the bottle can be checked to ascertain the pressure
bearing capacity of the bottle. Creep test is another important test that can be performed to see how
long the bottle can bear a predefined pressure.

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~Empty Bottle Height
~Base Clearance Test
This test determines the balancing property of the bottle. It calculates the depth of the base with
respect to the circumference. It is
very important to have the base as
per the specification of the
engineered design. Otherwise, the
bottle will topple when filled or
empty.

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Article XI. Aseptic line beverage blending
Pulp Dumping
2 Pulp Storage tanks
Capacity 6 KL
Diaphram pump
Centrifugal Pump
Pectin dumping hopper
Pectin mixing tank Capacity
3 KL
50 Brix Syrup
making in Syrup room
Simple syrup tank
Capacity 20 KL
R.O. Treated water in
Water treatment plant
Process water tank
Capacity 28KL
2 Ingredient and flavour
mixing tanks Capacity 500
LTR each
4 Blending Tanks Capacity 28
KL each
Transfer to UHT section
2 Pulp
Dumping
tanks each
500 LTR
Strainer CCP
Balance Tank Device
Preheating in Shell N Tube Heat
Exchanger
DE aerator
Homogenizer
Main Heating in Shell N
Tube Heat Exchanger
Holding inside Shell N
Tube Heat Exchanger

56 | P a g e
First Cooling
Second Cooling
Third Cooling
PET Aseptic Filling
line “SIDEL”
“Tetra Pak” Aseptic
Filling in Brick Packets
Aseptic Moulding, Filling
and Capping Machine
Form Fill Seal Packaging
machine
Labelling, Packet integrity testing
and End product Quality testing
Packet integrity tests and end
product quality tests
Automatic Palletizer unit
Storage/Warehouse
Shipping

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Article XIII. Good Manufacturing Practices (GMP)
Good Manufacturing Practice (GMP) is a system for ensuring that products are consistently
produced and controlled according to quality standards. It is designed to minimize the risks
involved in any pharmaceutical production that cannot be eliminated through testing the final
product.
GMP covers all aspects of production from the starting materials, premises, and equipment to
the training and personal hygiene of staff. Detailed written procedures are essential for each
process that could affect the quality of the finished product. There must be systems to provide
documented proof that correct procedures are consistently followed at each step in the
manufacturing process - every time a product is made.
10 Important Rules of GMP
Rule No. 1: Be sure you have the correct written instructions followed before any job is done.
Rule No. 2: Always follow those instructions EXACTLY with no ‘cutting corners’
“ASK IF U DON’T UNDERSTAND IF YOU CAN’T ASK DON’T DO IT”
Rule No. 3: Ensure that correct materials are being used.
Rule No. 4: Ensure that correct equipment is being used, and that is clean
Rule No. 5: Prevent contamination and mix-up
Rule No. 6: Always guard against labeling errors
Rule No. 7: Always work accurately and precisely
Rule No. 8: Keep things clean and tidy
Rule No. 9: Always be on look for mistakes, errors and bad practices, report them immediately.
“CONCEALING COULD COST LIVES”
Rule No. 10: Make clear, accurate records of what has been done and the checks carried out

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Article XIV. Good House Keeping Practices (GHK)
Effective housekeeping can help control or eliminate workplace hazards. Poor housekeeping
practices frequently contribute to incidents. If the sight of paper, debris, clutter and spills is
accepted as normal, then other more serious hazards may be taken for granted.
Housekeeping is not just cleanliness. It includes keeping work areas neat and orderly,
maintaining halls and floors free of slip and trip hazards, and removing of waste materials
(e.g., paper, cardboard) and other fire hazards from work areas. It also requires paying
attention to important details such as the layout of the whole workplace, aisle marking, the
adequacy of storage facilities, and maintenance. Good housekeeping is also a basic part of
incident and fire prevention.
Effective housekeeping is an ongoing operation: it is not a one-time or hit-and-miss cleanup
done occasionally. Periodic "panic" cleanups are costly and ineffective in reducing incidents.
Benefits of Good House Keeping
Effective housekeeping results in:
 reduced handling to ease the flow of materials
 fewer tripping and slipping incidents in clutter-free and spill-free work areas
 decreased fire hazards
 lower worker exposures to hazardous products (e.g. dusts, vapors)
 better control of tools and materials, including inventory and supplies
 more efficient equipment cleanup and maintenance
 better hygienic conditions leading to improved health
 more effective use of space
 reduced property damage by improving preventive maintenance
 less janitorial work
 improved morale
 improved productivity (tools and materials will be easy to find)

59 | P a g e
Article XV. CLEANING IN PLACE (CIP)
In modern food processing much equipment cleaning is automated in the form of cleaning in
place (CIP) system. A CIP system is a closed section of plant product followed by circulation
of a sequence of solution and water rinse that clean and then disinfect the plant leaving it
ready for resumed production. Though the initial capital investment is high, CIP offers a no.
of advantages. Its running costs are lower than traditional cleaning procedure. Since labour
costs are low and it gives optimal use of detergents, Disinfectants, Water & Steam.
As it does not involve the dismantling of plant prior to cleaning. CIP minimizes unproductive
down time and the risk of equipment damage during disassembly. It also safer since
personnel are no longer required to perform the sometimes hazardous operations of climbing
upon to or, into equipment and, providing the system is correctly formulated, it gives a
consistent result with little chance of human error.

60 | P a g e
Article XVI. EFFLUENT TREATMENT PLANT (ETP)
Section 16.01CHECKING PARAMETERS:
Parameter Inlet Range Outlet Range
1. Temperature
2. pH 6-8 6-8
3. TSS 200 mg/litre 50 mg/litre
4. TDS 2000 2000
5. COD 10,000 mg/litre <150 mg/litre
6. BOD 5000 mg/litre 20n mg/litre
7. DO
8. MLSS 5-6 3.5
9. O&G 300-500 5
Process Flow/ Procedure:
2. Bar Screen
3. Oil & Grease Skimmer
4. Equalization of waste
5. Oil Scrapper
6. Sump Tank
7. Digester (USABR)
8. Lime Reactor Tank
9. Primary Clarifier
1. Drainage water inlet
from manufacturing
plant

61 | P a g e
Effluent Treatment Plant or ETP is one type of waste water treatment method which is
particularly designed to purify industrial waste water for its reuse and its aim is to release safe
water to environment from the harmful effect caused by the effluent.
Industrial effluents contain various materials, depending on the industry. Some effluents
contain oils and grease, and some contain toxic materials (e.g., cyanide). Effluents from food
and beverage factories contain degradable organic pollutants. Since industrial waste water
contains a diversity of impurities and therefore specific treatment technology called ETP is
required.
The ETP Plant works at various levels and involves various physical, chemical, biological
and membrane processes to treat waste water from different industrial sectors like chemicals,
drugs, pharmaceutical, refineries, dairy, ready mix plants & textile etc.
10. Aeration Tank
11. Reaction Tanks
pH Balance
Poly Electrolyte
Poly
12. Secondary Clarifier
13. R.O. Treatment of
clarified water.
Sludge as by
product in
sludge storage
tanks
Drying of excess
sludge in filter
press
14. Use of treated water in
boiler & for gardening
purpose.
Selling of dried
sludge to cement
factories

62 | P a g e
Article XVII. Conclusion
During this semester training at VBL, I have had a lot of experience, knowledge and
exposure to the practical world that will be definitely fruitful to me in future endeavors. All
disclosures were awakening me in a boost of self-confidence to face life more challenging
now. Practical is a complement to the science or theory learned. This is clearly the concept of
science and charity, where they have learned without practice will be lost and will not give
anything - what effect. So if we do without the knowledge of course there will be problems in
terms of grip and stance ever - changing.
During my industrial training, there are many changes from the point of learning
environments and discussion among colleagues. It can directly increase the dedication and
rational attitude toward myself.
However, there are still some weaknesses that can be improved in the future. Therefore I
conclude that the industrial training program has provided many benefits to students even if
there are minor flaws that are somewhat disfiguring condition , so that this weakness can be
rectified in the future.
I can conclude that this industry is through training I received a lot of exposure in the
computing world. I would like to thank also the Sam Higginbottom University of Agriculture
Technology and Sciences giving students - students find their own experience with having
Industrial Training like this.

63 | P a g e
Article XVIII. References:
 WWW.PEPSICOINTERNATIONAL.COM
 WWW.BIS.COM
 WWW.ISOMANIFESTO.COM
 WWW.VBL.COM
 WWW.RJCORPASSOCIATION.COM
 WWW.FSSAI.COM
 WWW.WIKIPEDIA.COM
 WWW.TOI.COM
 WWW.QUALITYASSURANCEMAG.COM
 WWW.BUZZSOUTHAFRICA.COM
 WWW.BUSSINESSTIMES.COM
 WWW.SIDEL.COM
 WWW.KRONES.COM
 WWW.CONTIFEED.COM
 WWW.TETRAPAK.COM
 WWW.AQUAFINA.COM

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