INTERNSHIP REPORT

SRI PADMAVATI MAHILA VISVAVIDYALAYAM, TIRUPATI

M.Sc. INTEGRATED FOOD TECHNOLOGY

DEPARTMENT OF HOME SCIENCE

SUBMITTED BY

AKARSHITHA KARREE

ROLL NO- 2018INFT92017

HCCB – SRIKALAHASTHI.

SUMBITTED TO

IFT CO ORDINATOR
DR. G SIREESHA

M.SC INTEGRATED FOOD TECHNOLOGY

HOME SCIENCE

SRI PADMAVATI MAHILA VISVAVIDYALAYAM,TIRUPATI

YEAR 2018 - 2023

1
 INTERNSHIP PROJECT REPORT

HINDUSTAN COCA – COLA BEVERAGE PVT LTD, SRIKALAHASTHI.

(MAY-JUNE 2021)

Thallapaka Pravallika

M.Sc. Integrated Food technology

Department of Home science

Sri Padmavati Mahila Visvavidyalayam

Tirupati

Andhra Pradesh

2
 ACKNOWLEDGEMENT

I consider, it my prime duty to express my deep sense of gratitude to those, whose co-operate and guided me
in the completion of my internship program and project work.

I wish to express my sincere thanks to Prof. M.ARUNA, Head of the department of Home science, Sri
PADMAVATI MAHILA VISVAVIDYALAYAM , Tirupati, for providing the Internship Program,
timely assistance whenever it was required and for constant encouragement.

I sincerely thank Dr. G. SIREESHA , Coordinator of Integrated Food Technology for her continuous
guidance and support.I would like to thank the professors Dr. D. MADHAVI, Dr. M NIHARIKA, A. M
BEULAH, Department of Home Science, SPMVV for their constant support andguidance.

It is my great pleasure to express my heartiest sense of gratitude to FACTORY MANAGERMr. S

RAJKUMAR for permitted us to trained in this industry.

I also extent my heartful thanks to Mr. K.V.V.S.S.R PRAKASH RAO

( QA MANAGER ) , Mrs. B.MADHAVI ( QA TEAM LEADER )

I express my deepest sense of gratitude to Mr. K. VASU BABU ( FACTORY H R MANAGER), and Mr.
RAJESH KUMAR ( HR TEAM LEADER ).

At the same time, I extend my sincere thanks to all team leaders, executives, and operators in quality
department

THALLAPAKA PRAVALLIKA
M.Sc. INTEGRATED FOOD TECHNOLOGY

3
 INDEX

S.No TITLE PAGE NO.

1 OVERVIEW- INTERNSHIP OBJECTIVES 5

2 INTRODUCTION 6-9

3 LOCATION OF THE INDUSTRY 10-12

13-17
4
RAW MATERIALS FOR BEVERAGE PROCESSING
5 WATER TREATMENT PLANT 18-26

6 SYRUP PREPARATION 27-29

7 PRODUCTS MANUFACTURED 30-37

8 CARBONATED SOFT DRINKS 38-41

9 NON-CARBONATED SOFTDRINKS 42-45

10 TESTS FOR HOT FILL 46-48

11 PROXIMATE ANALYSIS AND QUALITY CONTROL 49-51

12 MICROBIAL ANALYSIS 52-56

13 CLEANING AND SANITISING OPERATIONS 57-58

14 EFFLUENT TREATMENT PLANT 59-62

15 CONCLUSION 63

OVERVIEW –INTERNSHIP OBJECTIVES

4
The following were the primary objectives that were to be achieved during internship:

1. To gain significant exposure regarding the day to day operations within the plant.
2. To understand the demand and needs of the industry.

To appreciate the real-world applications of food technology and to minimize the gap between
theoretical and practical knowledge.

5
INTRODUCTION

6
HINDUSTAN COCA-COLA BEVERAGE PRIVATE LIMITED

1. About Coca-Cola: Coca-Cola is created in 1895 by John Pemberton in Atlanta , Georgia.

Coca-Cola is sold in a local pharmacy only as a fountain drink. The 1916 introduction of
patented contour bottle made Coca-Cola instantly recognized from imitators by taste, sight,
and touch.

2. About Coca-ColaIndia: Coca-Cola the world favorite soft drink returned to Indian market in
1993 with its launch in Agra. The Coca-Cola system in India comprises 23 wholly owned
company operation and another 17 franchises owned bottling operations. A network or 29
contract packers also manufactures a range of products of the company.

3. About HCCBPL, Srikalahasthi :The srikalahasthi operations were acquired from its earlier
franchise in 2007 called Lakmi Balaji& as an immediate strategy set up as a sophistication
world class beverage of the Coca-Cola company. The project continued and became
operational from 2008.HCCBPL; Srikalahasthi is spread in a 91-acre area surrounded by
green paddy fields. Equipment with three production lines of 600 BPM and 200 BPM
capacities ,the factory produces :

 Carbonated soft drinks ( CSD): Coca-Cola ,Thumps Up, Sprite, Fanta, Limca
,Kinley soda.
 Non –Carbonated soft drinks: Maaza ,MMNF,MMPO,MMM,MMMF,MM pulpy
mosambi.

o size of the packaging includes 200m1, 300m1, in returnable glass bottle (RGB)• 400mi,
500m1, 600m1 750m1 , 1.25lit 135 in PET CSD and in case of PET HOTFLL line
400m1, 600m1, 1000m1 and 1.21it.

o Apart from these products there are other products which are unit outsource products that
it does not produce (e.g., cans, RGB, Maaza, Kinley water, etc.) from other Coca-Cola
manufacturing units to cater to the consumer demand in its territory.

7
The following gives in brief about the plant:

Total area 91 acres

Installed capacity 1000 Bpm/day

Green area 52 Acres

Build up area 15 acres

Effluents Treatment Secondary effluent treatment

Water source Bore wells

Bottling machinery Enhanced filtration and reverse osmosis

Brands produced CSD: Coca-Cola, Fanta ,Limca ,Sprite, Thumps Up, Kinley
soda.
NCSD: Maaza, MMM,MMNF, MMPO, MMMF
Packages produce CSD: 200 ml,300ml, 400 ml, 500 ml, 600 ml, 750ml, 1.25 lit,
1.75 lit.
NCSD: 400ml,600 ml, 1000 ml, 1200ml.
Leading brands 1. Thumbs up , 2. Sprite , 3. Maaza

Distribution mode 100% indirect distribution.

8
LOCATION

OF

THE

INDUSTRY

9
 LOCATION OF THE INDUSTRY

Location of the business is the most important factor influencing its success or failure.

Srikalahasthi unit is in Chittoor District and which is away 32 km from Tirupati city, 7 km from Srikalahasthi and 63
km from Chittoor city in Andhra Pradesh and having the force around 340.

Srikalahasthi unit is large scale industry and relates to both road and rail transport only. It has the 52 acres green
belt, which is surviving by effluent treated water. The Effluent treatment plant is sufficient to treat wastewater
generated from the plant.

Selection of the region:

Region for setting up this plant is selected based on the following factors:

Raw materials availability: Raw materials like water ,pulp, juice is sufficiently available in the surrounding
regions of the plant. Some of them are imported from other places, which are available for all types of
‘Transportation’.

Supply of labor:Availability of labor (both skilled &nonskilled) is good in the local area.

Supply of power: This plant purchase around 33 KV of power and plant has 33 KV transformer as main source of
power supply and 2 diesel generators of capacity 1600 KVA .

Climatic Factors: The plant is surrounded by green fields with good environment and is well suitable for beverage
production in the plant.

Government regulations and policies: This plant follows all the acts & regulations & policies. Some of
regulations & policies are safety and loss prevention management (OHSAS 18001), Food safety laws (HACCP)
,environmental management standards (ISO 14001) and Quality Management (ISO 9001).

Law & order : Company follows certain law & orders such as specific duty hours for the employees ,no child labor
,maintaining first aid facilities etc.,

Competitive industries :No competitive industries are existing

Selection of exact site:

Price of land : this unit bought the land at a rate in the accordance of company investment. The land is well
sufficient for all purpose of the units in beverage production.

Disposal of waste: This plant unit has good provision for disposal of waste at the generated sludge’s is handed over
the cement industries .

This plant is large scale industry and relates to both road and train facilities , but this unit using road transport only.

10
 RAW MATERIALS

FOR

BEVERAGE PROCESSING

11
 RAW MATERIALS

PROCUREMENT :

Any materials that used in its original or processed form in any after operations, involved in obtaining the desired
product is called as raw material.

The raw materials are produced and purchased in a continuous mode. The major raw materials like sugar, co2 ,
concentrate and pulp.

 RAW MATERIALS IN CORBONATED SOFT DRINKS

i. Sugar
ii. Concentrate
iii. Water
iv. carbon dioxide

 RAW MATERIALS IN NON-CORBONATED BEVERAGES

i. Sugar
ii. Water
iii. Concentrate
iv. Fruit pulp

SUGAR

At each delivery the sugar sample is drawn from at least 10 bags from different sites/ layers from the truck or from
the stores to obtain a composite sample . The sugar is then tested as per the frequency for the following parameters.

TABLE:1 TEST PARAMETERS FOR SUGAR:

S.NO TEST PARAMETERS

1 APPERANCE
2 TASTE
3 ODOUR
4 MICROBIOLOGICAL, TOTAL BACTERIA,YEAST, MOLD
5 FLOC POTENTIAL

CARBON DIOXIDE

Sample is collected from the liquid line of the co2 tanker as soon as it is received. The sample is then analyzed as
per the authorized testing procedures provided by the division in the carbonated beverage quality control manual

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TABLE :2 TEST PARAMETERS FOR CARBON DIOXIDE :

S.NO TEST PARAMETERS

1 PURITY
2 APPEARANCE
3 ODOUR
4 TASTE

FRUIT PULP / JUICE

Manufactured date, Batch no. By visual inspection is checked in case of AMP& TMP . Invoice , COC and COA
approval also checked. In case of pulpy orange only visual inspection is done.

TABLE .3 TEST PARAMETERS FOR PULP

PRODUCT TEST
Tottari Mango Pulp Brix, TOA, TTA,Microbiological parameters (Yeast & Mold , TPC,
Thermoacidophilic Bacterial, Heat Resistant Mold.
Alphonso Mango pulp

Aseptic Banana puree

White Guava Puree , Red papaya.

CONCENTRATE AND BEVERAGE BASES

“Coca-Cola India limited” ,Pirangut at Pune manufactures send the concentrates for srikalahasthi bottling
division .Only visual checks for presence of tamper proof seals/ damages and labels are done in case of concentrate
and beverages bases.

TREATED WATER

Regular analysis of water has been done to check all the quality related parameters . Treated water used for syrup /
beverage production is checked for appearance Taste , odor, Turbidity, P-Alkalinity-alkalinity, Total hardness and
residual chlorine at every four hours and iron content is checked once in a day.

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TABLE.4 SPECIFICATIONS FOR TREATED WATER

S.NO PARAMETER

1 Cl2
2 P-Alkalinity
3 Ph
4 T.D.S
5. M-Alkalinity
6. Turbidity
7. Iron
8. Chlorides
9. Sulphates

PROCESSING EQUIPMENTS

 Micro filters - To polish the water

 Rota meter - To measure the flow of fluids.
 Cooling tower - cool& recirculate water
 PHE - Cool the beverage, syrup, and water
 R O system - it purifies the water
 Homogenizer -homogenize the blended non-carbonated beverages
 Pressure tubes - Remove the salts by reverse osmosis method.
 Filter press - To filter raw syrup
 Hot fill PET filler - To rinse, fill and capping of NCSD
 CSD PET Filler - to rinse ,fill and capping of CSD
 Date coder - print the date, time, batch no and MRP
 CSD RGB - and capping of CSD
 ASEBI - Inspect the all surface of glass bottles
 Bottle washer - To wash the bottles

14
 WATER

TREATMENT

PLANT ( WTP)

15
WATER TREATMENT PLANT

Water treatment plant is the most important plant in beverage plants. Treated water for beverage preparation is
obtained from water treatment plant by different steps and various methods. The source water for the plant is the
bore wells. There are six bore wells which supply water the plant among that bore well is shallow type. Water
coming from bore wells is checked for the different quality parameters like turbidity, pH, alkalinity, total hardness,
chlorides, iron content, sulphites, TDS.

 Pressure sand filter

Chlorinated raw water is collected in the raw water tank. The water has certain amount of suspended
matter. To remove the suspended matter, a pressure sand filter has been provided.

The pressure sand filter is designed for a low forward velocity to ensure a high quality of outlet filtered
water. The sand filter is of mild steel epoxy painted construction. The water enters at the top and
percolates down through the bed. The suspended particles are trapped in the bed and filtered water exits
the vessel.

 OPERATION:

The raw water from the raw water storage tank is pumped to the top of the filter and is distributed through
the inverted bell mouth. As the water percolates through the inverted bell mouth. As the water percolates
trough, the filter media suspensions are retained in the media and clear water passes out through the
outlet. Free chlorine must be maintained at 6-8 ppm at outlet of pressure sand filter.

 ACTIVATED CARBON FILTER

The filtered and chlorinated water at the outlet of pressure sand filter may contain some trace organics. To
remove this trace organics and dechlorinate the water, an activated carbon filter has been provided.

 OPERATION

THE Filtered water from the sand filter is directed to the top of carbon purifier and distributed through the
bed of carbon the free chlorine and organics are removed from the water and purified water flows out of the
outlet.

 REVERSE OSMOSIS UNIT

To determine the water, a reverse osmosis unit has been provided. The passage of the dissolved salts and
organic in the feed water is restricted by the R.O membrane and these get concentrated in the water or
brine.

16
 FLOW CHART

BORE WELLS

RAW WATER STORAGE TANKS (350kl + 350 kl)

Clarifier ( 145 kl ) flow 35 m3 /hr. Pre-R.O Sand filter ( 25m3/hr.)

Clear well (20m3/hr.) Pre-R.O carbon filter

Pre-R.O 5-micron filter
PSF filter (20 m3/hr.)
R.O membrane filter
Dichlorination ( ACF) 20m3/hr.
Degasser tower
Softener 20 m3/hr.
Process water 3-5 ppm
Un chlorinated soft water (40 kl) De chlorination ACF 25m3/hr.
for boilers Lead and lag ACF 25 m3 /hr.
5-micron filter
Chlorinated soft water(1-3 ppm)
for bottle wash U.V treatment

I Micron filter

17
  Test to carried out in treated water:

Treated water will conforms as follows:

 PH
 SUSPENDED SOLIDS(PPM)
 TOTAL DISSOLVED SOLIDS ( PPM)
 ALKALINITY
 SULPHATES (PPM)
 CHLORIDES
 TOTAL OF SULPHATES AND CHLORIDES
 IRON (PPM)
 TURBIDITY (NTU)
 MICROORGANISM INDICATORS
 TOTAL COUNT
 ALUMINIUM
 COLOUR/TASTE

SOME OF THE STANDARDS TO BE MAINTAINED IN TREATED WATER

PH MIN . 4.9
TDS <500mg/lit
ALKALINITY <85 mg/lit
TOTAL HARDNESS <250 mg/lit
CHLORIDES <250 mg/lit
SULPHATES <250 mg/lit
TURBIDITY <0.3 NTU
IRON 0.1 mg/lit

ALKALINITY DETERMINATION IN WATER

DEFINITION OF ALKALNITY

Alkalinity is a measure of amount of OH -, CO 32- and HCO32- . This neutralizes acidity in water. It is expressed as
mg/L or PPM of CaCo3.

PROCEDURE OF ALKALINITY TESTING

 Measured water sample

 Add 2 drops of phenolphthalein
 Titrated against 0.02 N H2SO4.
 End pink to colorless.
 Note down Burette readings & Add 2 drops of Methyl Orange
 Continue titration with 0.02 N H2SO4.
 End yellow to reddish orange

18
M- ALKALINITY P- ALKALINITY

19
TOTAL HARDNESS DETERMINATION IN WATER

DEFINITION OF WATER HARDNESS

The simple definition of water hardness is the amount of dissolved calcium and magnesium in the water. Hard water
is high in dissolved minerals, largely calcium and magnesium .

PRINCIPLE OF HARDNESS ( EDTA)

The hardness producing ions ( Ca2+ and Mg 2+) present in the water combines with Eriochrome black –T (EBT) to
form an unstable complex (wine red).

When titrated with EDTA (Ethylene diamine tetra acetic acid) , the Ca 2+ and Mg2+ moves from EBT TO EDTA to
form a stable complex at pH 9-10 leaving free EBT ( Steel Blue ).

PROCEDURE OF HARDNESS TESTING

 Measured water sample.

 Add 5-6 drops of ammonia buffer.
 Add a Pinch of EBT indicator .
 Titrate against 0.02N EDTA ( Ethylene diamine tetra acetic acid ).
 End Point Wine red to steel blue.

wine red
steel blue

CHLORIDES DETERMINATION IN WATER

DEFINITION OF CHLORIDES:

The chlorides ion is the anion (negatively charged ion ) Cl - . it is formed when element chlorine gains an
electron or when a compound such as hydrogen chloride is dissolved in water or other polar solvents.
Chlorides salts such as sodium chloride are often very soluble in water.

PROCEDURE OF CHLORIDES TESTING:

 Measured water sample

 Add 2-4 drops of potassium Chromate ( K2CrO4)

20
  Titrated against 0.02 N Silver Nitrate AgNO3
 End Yellow to Brick Red.

CHEMICALS ADDED IN CHEMICAL COAGULATION SYSTEM:

Hydrated lime – Reduces alkalinity and temporary hardness.

Calcium hypochlorite – kills micro- organisms, removal ofodor , removal of turbidity, by oxidation of
organic matter.
Ferrous sulphate – coagulation for removal of suspended particles act as pre- filter.

21
 SYRUP

PREPARATION

22
 SUGUR SYRUP PREPARATION

Sugar syrup is one of the raw materials for final beverage.

INGREDIENTS USED FOR SUGAR SYRUP PROCESSING IS

 Sugar (Refined sugar)

 Water
 Carbon
 Hyflux

Processing steps for sugar syrup preparation

Dumping of sugar:

 Take the required amount of water into raw syrup tank through water level scale.
 Heat the water to 850C using steam and then start dumping of required amount of sugar. Sugar bags should
be reweighed before dumping.
 Give a gap of 5 mins for every bag of sugar dumped to maintain the temperature level of water.
 NOTE: here no direct heat is applied to water. In place of it they use steam for better quality.
 Dump a bag less than required amount. Once dumping is over , weigh the empty bags and calculate the
balance amount of sugar to be added. And add the remaining sugar.
 Once dumping is over, clean the dumping chute with treated water and
 Lock the door. wait till temperature reaches 850c
 Give a contact time for 30 minutes

Addition auxiliary materials:

The auxiliary materials used in sugar syrup are:

ACTIVATED CARBON: It is the special type of carbon which is chemically treated for enhanced adsorption
properties to remove off-color impurities from sugar.

HYFLO SUPERCEL: It is a special type of fossil flour used as a filter aid to filter the raw syrup.
 Add the required amount of activated carbon (0.3% ) and mix thoroughly . Stir vigorously and all allow
settling for 30 minutes
 Add the required amount of Hyfluxsupercell (0.3%) prepared earlier to the raw syrup tank. give a contact
time of 30 minutes.

Sugar syrup circulation through filter press:

 The filter press contains 22 filter papers. The filter papers are given with pre–coating using hyflo supercell
to ensure filtering.
 Circulate the sugar syrup between raw syrup tanks and filter press for 30 mins.

Cooling of sugar syrup:

 The filtered syrup is passed through the plate heat exchanger. PHE contains glycol and water on both sides
of syrup .
 Syrup is decreased to 60- 650c and then to 250c by glycol.

The syrup obtained is simple syrup and is sent to carbonated soft drinks and hot fill separately for preparation of
final beverage.

23
 PRODUCTS

MANUFACTURED

24
Products manufactured in HCCBPL Srikalahasthi:

CABONATED SOFT DRINKS (CSD) :

 Coca –cola
 Thumps up
 Fanta
 Sprite
 Limca
 Kinley soda

NON-CARBONATED SOFT DRINKS ( NCSD )

 Maaza
 Minute Maid Pulpy Orange
 Minute Maid Nimbu Fresh
 Minute Maid Mango
 Minute maid mixed fruit.

Coca-Cola:

The Coca-Cola is world’s favorite drink in beginning in 1886. It is originally marketed as a temperance drink and
intended as a patent medicine, it was invented in the late 19 th century by John Stith Pemberton and was bought out
by businessman Asa GriggsCandler, whose marketing tactics led Coca-Cola to its dominance of the world soft-drink
market throughout the 20th century. The drink name refers to two of its original ingredients — cola leaves and kola
nuts.

25
Thums Up

It is most popular soft drink in India. It has strong Cola taste and made for person with exciting personality. It has
strong fizzy taste. It was introduced in 1977 to offset the with drawl of the Coca-Cola company from India. The
brand was later bought by Coca-Cola who re-launched to compete against Pepsi

Fanta:

Fanta is a brand of fruit flavoured carbonated drinks marketed globally created by the coca-cola company, the
current version was created in Italy. It is identified as fun catalyst. Fanta stands for its vibrant colour, tempting taste
and tangling bubbles that just uplifts feelings but also helps free spirit

SPRITE:

Sprite is a colorless, caffeine-free, lemon- and lime-flavored soft drink created by the Coca-Cola company in
1961 as a competitor to 7up. Worldwide sprite is ranked as the no.4th soft drink and sold in more than 190 countries.
Today sprite is perceived as 'youth icon' and it has grown to be one of the fast-growing soft drinks in India. It is
available in glass, PET containers, can and fountains of various sizes.

26
LIMCA:

Limca is a lemon- and lime flavored carbonated soft drink made primarily in India and certain parts of the U.S. it
contains 60 calories per 150m1 can. The formula does not include fruit, relying instead on artificial flavors. The
success formula is sharp fizz and le-noni bite combined with the single-minded propositions of the brand as the
provider of freshness.

Kinley SODA:

Kinley is a brand of still or carbonated water, it is one of the best sparkling carbonated soft drink without any added
flavor.

27
NON-CARBONATED SOFT DRINKS:

MAAZA:

Maaza currently dominates the fruit drink category. It offers the same real taste of fruit juices and is available
throughout the year. Maaza was launched in 1976. Consumers regard maze as wholesome, natural, fun drink which
delivers the real experience of fruit.

Minute Maid Pulpy Orange (MMPO):

The minute maid company is owned by the Coca-Cola company, the world's largest marketer of fruit juices and
drinks. Minute maid was the first company to market orange juice concentrate by eliminating 80% of the water in
orange juice, forming frozen concentrates that whenreconstituted created orange juice.

28
Minute Maid Nimbu Fresh (MMNF):

Recently Coca-Cola launched new fruit drink minute maid nimbus fresh which is made from fresh lemon juice
concentrate. It tastes like a homemade nimbussherbet. It is made without addition of any preservatives.
Commercially available in PET bottles and Tetra Pack.

Minute Maid Mango (MMM):

Coca-Cola beverages Sri Lanka has launched Minute Maid Mango, its latest innovation under the Coca-Cola
company's international Minute maid juice brand. MMM is a mango flavored juice drink that offers an unmatched
taste experience to consumers due to the presence of real mango pulp, offering a tangy taste and natural goodness.

29
MINUTE MAID MIXED FRUIT JUICE:

The minute maid company is owned by the Coca-Cola company, the world's largest marketer of fruit juices and
drinks. Minute maid mixed fruit juice is a combination of fruits like mango, banana, guava, and papaya into one
harmonious mixed fruit drink.

30
 CARBONATED

SOFT DRINKS

CARBONATED SOFT DRINKS (CSD) :

In plant carbonated soft drinks are bottled in both Returnable Glass Bottles (RCD) and Polyethylene Terephthalate
(PET) bottles. The only differences in bottling is packaging material. Carbonated soft drinks are manufactured with
water, sugar syrup, Co2, Concentrate and beverages bases .

Beverage bases are of two types:

 Dry base beverage

 Liquid base beverage

31
RGB – CSD MANUFACTURING PROCESS:

HEATING THE PREFORM

Heating is done in an oven which is in shape of caterpillar. Heating is dividing into horizontal layers. These layers
are capable of individual control parameters is to control the distribution of the PET throughout the bottle . The
temperature at which the perform is suitable for blowing into the finished bottle is approximately 90 0 c – 1250 C.

Different sizes of performs for different bottles:

SIZE (CM) BOTTLE ( LIT)

25.7 CM 400-750ml
37.7 CM 1.25 lit
46.7 CM 1.75 lit

STRECHING THE PREFORM

It is necessary to orient the material within the confines of the blow mound, with stretching the bottle would form
initially in the neck area then later the feet would form because the material would be hit the side walls of the mold.
The main blow pressure usually is set at 40 bar. The purpose of the main blow pressure is to complete the final
profile of the bottle .

FLOW CHART
PET FILLING

Blowing

Rinsing with potable chlorinated soft water ( 1-3 ppm)

Filling & Capping
32
 warming

Labelling
Date & Batch

Final Inspection

Secondary packing

palletizing

Warehouse

DIAGRAM : PREFORM

33
NON – CARBONATED BEVERAGES

34
NON – CARBONATED BEVERAGES

PET – NCB

In this plant Non-carbonated soft drinks are filled only in PET bottles. For NCSD the main ingredients are pulp,
concentrate , Simple syrup and water.

The pulp differs from one product to another

FOR MAAZA: Totapuri mango pulp and Alphonso mango pulp is used in 6:1 ratio.

FOR MMPO: Orange juice and orange sacs are used

FOR MMNF: lemon juice is used

FOR MMM: Only Neelam mango pulp is used

FOR MMPM: Mosambi juice and mosambi sacs used

Concentrate or beverage base:

A mixture of flavors, acidulant and coloring material and preservatives produced by the coca- cola company.

Blended Beverage :
It is uniform of simple syrup, fruit pulp and concentrate / beverage after adjustment to final volume with treated
water

Ready Beverage:

35
Blended beverage when homogenized at 2500 psi pressure forms a homogenized mixture of ready beverage

Thawing:
Thawing is done to bring frozen pulp at -180C to room temperature for duration of 16 hours.

Pulp and Concentrate transfer system:

The pulp and concentrates / beverages base are transferred to pulp and concentrate transfer systems respectively.
From the transfer system, the pulp and concentrates are transferred to blend tanks.

Blending:
In blend tanks, the pulp and concentrates are blended with the syrup. The blended pulp is tested for parameters ,
further processing will not be done.

Homogenization:
The blended beverage is passed through homogenizer for reduction in particle size from more than 15 micron to < 3
micron. pressure in the homogenizer is 2500psi. The capacity of the homogenizer present in our plant is 10500
lit/hr.

Ready Beverage:
Ready beverage is collected, and final volume and final brix are adjusted. The ready beverage is stored in ready
beverage tank for further processing.

Pasteurizer:
It is mainly used for sterilization of juice beverage ( Non-carbonated). The plant is designed for direct filling of the
product

NON-CARBONATED SOFT DRINKS (NCSD) :FLOW CHART ( NCSD FILLING )

Blowing Simple syrup + pulp & beverage

TESTS
Rinsing with potableFOR HOT
chlorinated soft –FILL Ready beverage
Homogenizer
Filling &water
Shrink ( 1-3 ppm)
capping
tunnel
Ready beverage

Bottle conveyor
pasteurizer

36
Cooling tunnel
HOT - FILL PROCESSING

TEST SAMPLE POINT

Sensory(taste/odor/appearance) Packaged beverage
Foreign material Packaged beverage
Brix ,assay ,syrup, beverage ratio, throw Packaged beverage
Titrable acidity Packaged beverage
Product temperature Packaged beverage
Yeast and mold Packaged beverage
Hydrogen peroxide residual Packaged beverage

MANGO PULP:

Used in hot filled maaza and minute maid mango . Mango is microbiologically most critical raw material.

TOTAPURI MANGO PULP (TMP):

APPEARANCE:

Moderately viscous golden yellow with no signs of browning, specs, insects, and other foreign material.

TASTE AND ODOUR:Sweetish sour, sour characteristic aroma, and mild taste of mango odor.

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BRIX :14.0 -18.0

ACIDITY: 0.3- 0.8

PH : 3.6 – 4.2

ALPHONSO MANGO PULP:

APPEARANCE:

Moderately viscous orange yellow flowing liquid , no obvious sign of browning or gelatinous particles.

TASTE AND ODOUR:

Sweetish sour, characteristic aroma, and rich taste of mango puree.

BRIX: 17.0 – 20.0

ACIDITY: 0.3 – 0.8 %

PH : 3.6 -4.2

PROXIMATE ANALYSIS
AND

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 QUALITY CONTROL

FINISHED PRODUCTS:

1. Vacuum test:

Purpose: To measure vacuum in the finished NR PET Maaza bottle.

Equipment:
 Zahm & Nagel vacuum Tester.
 Calibrated vacuum gauge
2. Torque test:

Purpose: To determine the torque in PET finished product.

Equipment:
 Torque tester
 Bottle chuck

3. Net content test:

Purpose: To determine the Net content of the Carbonated Soft Drinks or Non-Carbonated juice products to
ensure the Beverage volume in the bottle meets the company specification.

4. Gas Volume:

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 Purpose: To the carbonation level in the final beverage.

Equipment:
 Zahm & Nagel Gas Volume tester.
 Fahrenheit Thermometer.
 Leather Safety Guard.

Crown closure test(RGB) :

Purpose:To ensure that application of crown on the glass bottle is intact and proper.

Equipment: Crown crimping with a GO-NO GO Crimping Gauge.

BRIX TEST:

PURPOSE :To measure the brix of beverages ( carbonated or Non – carbonated) or simple syrup samples.

EQUIPMENT:

 Density
 Disposable syringe ( 5 or 2 ml)
 100 ml beakers
 Distilled water

DENSITY

EQUIPMENT : Density meter

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 MICROBIAL ANALYSIS

MICROBIAL ANALYSIS

Water ,CTP final rinse water, finished products ( NCB,CSD) , Packaging materials ( closures) and ready beverages
are analyzed for microbial.

MICROBIAL ANALYSIS FOR WATER:

Raw water , treated water, soft water is taken for analysis. In these 3 types of water coliform and TPC is done.

Coliform:

Incubation Temperature - 350c+20c

Incubation Time - 24 hrs.

Sample Size - 100ml

Technique - Membrane Filtration

Filter Paper size - 0.45-micron meter

Coliforms - <0/ml

TPC:

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Incubation Temperature - 35+20c

Incubation Time - 48 hrs.

Sample Size - 10 ml

Technique - Membrane filtration

TPC - < 25/ml

Microbial Analysis for CTP Final Rinse Water :

In this Yeast & Mold and TPC is done

YEAST & MOLD :

Incubation Temperature - 25 + 20c

Incubation Time - 120 hrs.

Observation - after 48 hrs. intervals up to 120 hrs.

Techniques - Membrane filtration

Sample Size - 100ml

Yeast & mold - < 10/100ml

TPC

Incubation Temperature - 35+20c

Incubation Time - 48 hrs.

Sample Size - 10ml

Technique - Membrane Filtration

TPC - < 25/ml

Microbial Analysis for finished products :

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Non - Carbonated Beverages :

Yeast & Mold :

Incubation Temperature - 25 + 20c

Incubation Time - 120 hrs.

Sample Size - 2 ml

Technique - pour plate method

Yeast & Mold - < ½ ml

TPC:

Incubation Temperature - 35+ 20c

Incubation Time - 48 hrs.

Sample Size - 2ml

Technique - Pour plate Technique

TPC - <5/2 ml

CARBONATED SOFT DRINKS :

Yeast & mold

Incubation Temperature - 25 + 20c

Incubation Time - 120 hrs.

Sample Size - 20 ml

Technique - Membrane Filtration

Yeast & Mold - <10/20 ml

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CLEANING AND SANITISING
OPERATIONS

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CIP SECTION

CIP is common for both carbonated and non-carbonated beverages . if can be done by two processes.

 CIP : Clean in place

 COP: clean out of place

The CIP is done by 2 ways :

HOT CAUSTIC CIP: Hot CIP means, in this caustic lye solution at 85oc is used.

COLD CAUSTIC CIP: Cold CIP means , in this OSA – N is used.

CIP is done for : Process Equipment, Pasteurizer, and filler ,CSD filler.

CIP IS DONE IN

6 Steps 3 step 3 step Hot water

o Rinse Pre – rinse Pre- rinse

o Lye dosing Lye – dosing Water
o Lye circulation Lye circulation Final rinse
o Rinsing Lye recovery
o Acid dosing Final rinse

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o Acid circulation
o Rinsing
o Sanitation
o Rinsing

EFFLUENT
TREATMENT PLANT

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EFFLUENT TREATMENT PLANT :

Collection tank

Removal of oil

Neutralizer

Anaerobic tank

Biox tank
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Aeration tank
DESCRIPTION :

BAR SCREEN / GRID CHAMBER: This chamber removes all the particulate matter like plastic cover , straws,
non- biodegradable matter by mesh provided.

OIL SKIMMER: Oil which came through influent is separated with help of oil skimmer belt , after that this water
is flowing to collection tank.

COLLECTION PUMP: Once the collection pump attains the level above the foot valve, start the collection pump
and collect the raw effluent into any one of the equalization tanks.

Equalization tank : Check the pH of the equalization tank. PH should be between 7.0 – 8.5 . If the pH is < 7.0 ,
then required amount of caustic is added to increase the pH . Diffused aerators are providing to mix the effluent for
proper equalization and neutralization . After confirming the p H , start the effluent pump and take the water into
the anaerobic tower.

Anaerobic tower : Anaerobic bacteria are present in the anaerobic tower, which acts on the raw effluent and
reduces the BOD and COD load. During this process the anaerobic bacteria produces methane and other gases .
From the anaerobic tower , the effluent is taken into the BIOX tank ( pre – aeration tank ).

Pre – aeration tank : Aerobic bacteria are present in the box tank, which acts on the effluent and further reduces
BOD & COD load up to some extent . maintain DO>2.0 ppm. Aerobic bacteria are present in the aeration tank,
which acts on the effluent and reduces BOD & COD load to the desired level.

Maintain MLSS concentration of 2000- 350 mg/I in the aeration tank for effective reduction of organic matter. After
aeration tank, water flows into the secondary clarifier.

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Secondary clarifier: the slides present in the water fromthe aeration tank settle down at the bottom of the
secondary clarifier and only clear water overflows. The settled sludge is again recycled into the aeration tank to
maintain the required MLSS concentration.

Whenever the MLSS concentration increases more than 3000mg/l, drain the sludge into sludge drying beds. After
secondary clarifier, water is taken into the treated effluent collection tank, after addition of chlorine to disinfection.

Treated effluent collection tank:

Chlorinated treated effluent water is subjected to proper chlorine contact period for 40- 60 min. This discharged
water limited to 0.1 ppm of free chlorine contact and the same is pumped to green belt pond which is away from
1800 feet from the discharge pump to water the plants.

The free chlorine will be normally nil at storage pond, the same is confirmed by random checking.

The treated water quality is confirmed through fishpondbioassay before discharge to the green belt. Plant is having
facility to take back the discharge to the green belt. Plant is having facility to take back the discharge water for
treatment in case of process failure.

CONCLUSION:

During In- plant training, I learnt a lot about technical skills, working skills and punctuality. I learnt a lot about
industrial culture, safety precautions to be followed and how to maintain discipline in the industry. Everyone
supported me in learning the processing skills and quality management. Managers, Team leaders, executives,
Operators helped us a lot during my in – plant training.

REFERENCE:

HCCBPL, Srikalahasthi operations,

 Website:-

 www.cocacola.com
 www.cocacolaindia.com
 www.google.com

THANK YOU
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