An Industrial training on QUALITY CONTROL

LUMBINI BEVERAGE PVT LTD HAJIPUR BIHAR ,844101

INDIA

PEEYUSH KUMARBIOTECHNOLOGY

2011-2015NIT JALANDHAR

Index

• Introduction

• Water treatment process

• Product manufacturing

• Microbial test

• Bottling plant

• House keeping

• Effluent testing

• Safety and quality test

INTRODUCTIONPepsiCo is a major producer of carbonated soft drink, otherbeverage and snack food .It is sold in stores and restaurant, retailoutlet and through vending machine . Its beverage divisionincluding Pepsi cola drink , water bottles and markets severalpopular drink . USA based company PepsiCo acquire Tropicanaand Frito lay .PepsiCo's soft drink products are -• Pepsi • Mountain dew • Marinda • Lehar Evervess soda • Slice • Aquafina • 7UP

WATER TREATMENT PLANT • The LUMBINI BEVERAGE plant has one of the most advanced

purifying water process. Producing soft and treated water .• Soft water (up to ion-exchange process )-cleaning machines, bottle

washing, cleaning plant ,cooling plant and general use .• Treated water – For syrup preparation.

There are different storage tanks and different processes for producing treated water (as shown in flow chart )• For coagulation , we have coagulation tank of capacity 80kL with

flow rate of 370lit /min . Chemicals Composition Bleaching powder Ca(ClO)2 6%Lime Ca(OH)2 8%Ferrous sulfate FeSO4 10%

• The Sedimentation process is carried out in intermediate tank of 40KL.

• Sand filter is removes bulky object such as gravel particle and material that run off from soil .

• Sand filter purify water under three different process.

(a) Mechanical straining

(b)Flocculation and sedimentation

(c)Electrolytic changes

• Activated carbon filter – Property of absorbing and attracting impurities such as gases , color liquid and finely divided solid .

• Micro filter –Water is filtered trough micron filter(polyamide ) of void size 5 micro-meter .

• UV Filtration –At last water is filtered through UV light of wave length 1000 - 4000 angstrom .

Testing of treated water

• Total hardness

• Total chlorides

• Turbidity and pH

• Total solids

• Alkalinity

RESULT :• By chemical coagulation and flocculation :

a) Expected microbe reductions 90-99%, if critical process variables are adequately controlled.

b) No microbe inactivation by alum or iron coagulation

Infectious microbes remain in the chemical floc

c) The flock removed by settling and/or filtration must be properly

managed to prevent pathogen exposure.

• By sand filtration :

a) Effective in removing enteric microbes from water.

b) Virus removals >99% in lab models of slow sand filters.

MICROBIAL TEST IN WATER TREATMENT PLANT

Sample Sampling point Test Specification

Raw water Raw water tank TBC & coliform TBC (<10,000

CFU/g)

& <10 coliforms/g

Treated water Sand filter /ACF tank TBC & coliform TBC (<10,000

CFU/g)

& <10 coliforms/g

Syrup sampling Syrup tank

before addition of

concentrated

Yeast & mold <100 yeast &

mold/g

Ref – PepsiCo quality control booklet

BOTTLE WASHING :From microbial point of view it is very necessary to wash bottle for beverage use ,is treated in following manner .There are seven segments and each segment take about 20 minute to pass next segment .

• Pre rinse : Rinse by soft water

• Pre wash: Bottle is washed at 50°C to 60°C by caustic jetting .

• Soak 1: Bottle is dipped in low percentage (1.0 – 1.5%)of caustic at temperature of 55°C to 60°C .

• Soak 2: Bottle is dipped in high percentage (2.5-3.0%) of caustic at temp 72°C to 77°C .

• Hydro : Rinse by soft water .

• Pre final wash: Bottle is dipped in warm water in presence of 1 ppm chlorine .

• Final wash : Bottle is again dipped in 1 ppm of chlorine

containing soft water .

PRODUCT MANUFACTURING :• Treated water is used for manufacturing of soft

drinks , soda water etc.

SYRUP PREPARATION :

1. Tank and pipeline sanitation

2. Water heating and sugar dumping

3. Filtration

4. Simple syrup calculation

5. Concentrate addition

6. Final syrup calculation

PREPARATION AND BOTTLING OF SOFT DRINK:

Tank syrup

Cooler

Packed bottle

Prepare beverage

Bottling and filling

CO2 tank

PRODUCT TESTING:

There are following tests-

• Methylene blue test:

To detect mold in bottle.

• Inverted brix test :

To check sugar content after 24 hours of bottling

• Caustic carryover test :

To check the level of alkali in bottle .

EFFLUENT TREATMENT PLANT The main aim of effluent treatment is to remove the settle ablesolids, floating particles ,oil and grease and also reduce thebiological and chemical oxygen demand (BOD & COD ).

Effluent treatment process :

• Bar tank: Store waste water directly coming from plant

• Equalization tank:Acid is mixed for effluent neutralization

• Digester :Anaerobic waste treatment is performed

Contd.Primary clarifier :

There is an agitator in primary clarifier to agitate the sludge which is settled at the bottom.

• sludge beads :

The sludge bead provide to drain the water from concentrated sludge from primary and secondary clarifier .

• Aeration tank :

Secondary treatment is performed by biological process.

Secondary clarifier :

To maintain the required MLSS ( Mixed liquor suspended solids)

in aeration tank and excess sludge is pump to sludge bed at

regular interval .

E.T.P TEST

• Total acidity

Measure total acidity of effluent sample by sodium

hydroxide

• Total dissolve and suspended solid

• Dissolve oxygen

• Chemical oxygen demand

• Biochemical oxygen demand

Thank You !!!