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Transcript of Training 03
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CHAPTER 1
INTRODUCTION
1.1 Industrial TrainingIndustrial training provided real world experiences to explore the relevant knowledge
and skills which are required to enter into a particular career field and pre-
professional work experience with specific assignments and responsibilities. An
Industrial Training is very important to attain good working experience in an
organization by applying theoretical knowledge into practical situations. ecause
theoretical knowledge along is not enough to do a professional career in future
industrial world.
Internship is an excellent way of building communication skills and decision making
abilities in a working environment and it is more helpful to develop work ethics of
the organizational culture and behavior.
1.2 Objectives ! t"e training
1.2.1 #ain bjectives
!. To gain knowledge about the way of applying theoretical knowledge into
practical situations.
". To experience and understand real life situations in industrial organizations
and related environments.
1.2.1 $%eci!ic bjectives
To improve communication skills and decision making abilities in a working
environment.
To understand about the formal# informal relationships in an industrial
organization and ethics and behavior of the organizational culture.
To gain knowledge on pre-professional work experience with specific
assignments and responsibilities.
To gain knowledge about way of promoting favorable human resources in
teamwork to achieved targets.
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1.& Organi'atin ! t"e re%rt
The information about industrial training placement of $ountry style food %&'T( )td
was collected before entering training. And the information about product processes
was studied during the training period. *orking with managers# supervisors of the
factory and labours were gave great experience. Training was done according to the
time table under supervision.
The introduction and ob+ectives of industrial training is included in the chapter one
according to my point of view. The second chapter contained overall idea of the
company is given with the description# as the business process and organizational
hierarchy. ,escribe about the training experience and training activities are includedin the third chapter. $hapter four explains limitations# issues experienced while
working in the organization and the suggestions that can be offered in the point of
view of the student. And conclusion of whole program technologies# learning and
experience include throughout the industrial training period with the flow diagrams.
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CHAPTER 2
CO#PAN( )AC*+ROUND
2.1 Overvie, ! C-%an$ountry style food %&'T( )td is the pioneer in fruit based ready to serve beverage
industry in ri )anka which is located in adawatha. It started in !/0! to
manufacture and market a range of food products under the brand name 12A3 to
meet the needs of the ri )ankan and 4xport 2arkets. *ith the growing demand for
its products in international markets# currently the products are exported to Australia#
5ew 6ealand# Italy# 7nited ingdom# 8ermany# $anada and 2iddle 4ast since !//9.
The 2A products are manufactured under strict hygienic conditions and quality
control in order to maintain its highest quality. The whole fruit based beverage range
of 2A is ) certified for its quality. $ountry tyle :oods %&vt( )td. was
awarded with three prestigious International standardization certificates; I< ""999#
=A$$& %=azard Analysis and $ritical $ontrol &oints( and 82& %8ood
2anufacturing &ractices( by the ri )anka tandards Institution %)I( in "9!>.
=owever it is the zero waste company pioneers in ri )anka. 2A is en+oying the
market leadership for last two decades in the local fruit base beverage market
segment. Today# 2A has become one of the market leaders in the fruit drinks
industry in ri )anka living up to its slogan 1:ull of 5atural 8oodness3.
2.1.1 /isin ! t"e C-%an
To be among the corporate leaders in the natural based food and beverage industry#
and cater to a wide range of markets with a wide range of products.
2.1.2. #issin ! t"e C-%an
To achieve total productivity in the natural based food and beverage industry#
manufacturing under strict hygienic conditions# being mindful of health and wealth
of the entire society.
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2.2 Nature ! business
$ountry tyle :oods %&vt( )td manufactures fruit drinks# herbal drinks and milk
added drinks from the specially selected ripe fruits# best quality herbs and fresh milk
respectively. They packed their products in !/9ml glass bottles# &4T bottles and tetrapack. Apart from that $ountry tyle :oods %&vt( )td market trading items with the
brand name of 2A such as drinking water# $hoco bubbles# wafer sticks and
12A3 bites %naks( under the strict quality supervision.
2.2.1 0ruit Drins
2ixed :ruit ,rink
2ixed :ruit with )ime ,rink
*ood apple ,rink
)ime ,rink
&ineapple ,rink
2ango ,rink
&apaya 2andarin ,rink
&assion ,rink
Anoda ,rink
Amberella ,rink
2.2.2 Herbal Drins
8inger ,rink
4ramusu ,rink
Tamarind ,rink
2.2.& #il added Drins
$hocolate ,rink
herbet ,rink
$offee ,rink
2ango last ,rink
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2.& Organi'atinal $tructure
:igure ".!@ :low chart of
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CHAPTER &
EARNIN+ OUTCO#E$
&.1 3ring E4%erienceThese areas was covered successfully within three months of industrial training
period#
2ain purchasing stores
:ruit stores
:ruits washing section
8lass bottles washing section
8lass bottle checking section
:ruit cutting B pulp production
!/9ml glass bottle retort section and labeling section %for milk drinks(
!/9ml glass bottle labeling section %for fruit drinks(
:ruit nectar filling section
:ruit nectar labeling section
Tetra pack division
)aboratory
Cuality assurance department
I worked at each of the above sections as a labour to a gain the experience and
observed all the process which can apply theoretical knowledge in practical way. The
knowledge of Accounts and 4conomics was applied in the purchasing division.
=owever theoretical knowledge of the sub+ects which learned in the university were
more helpful to understudied the process of the company. The quality of raw
materials and final products were checked and that was wonderful when working in
the industry. 2achine repairing# cleaning and machine operating were observed and it
is more important to gain knowledge as a student of specialized in food engineering.
2achine operating# cleaning and the process of production of Tetra pack was a great
experience. ome milk tests# brix test were done and other tests were observed.
Industrial training at $ountry tyle :oods %&vt( )td was very important to gain a
great experience and knowledge about way of applying theoretical knowledge into
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practical situations and to understand real life situations in industrial organizations
within related environments. This was a great experience with nice people.
&.2 Training Activities&.2.1 #ain %urc"asing stre
Eaw materials# spears and other required services are acquired through purchasing
division. 2aterials which required mainly for the production process such as fruits#
additives# packing materials and milk are considered as the main purchasing items.
&urchasing division is followed company standards and I< ""999 standard to
purchase goods.
&.2.1.1. Objective ! Purc"asing
&urchasing good quality raw material from the supplier# provide the good quality raw
material to the production and issuing good quality final product to the consumers.
&.2.1.2 Purc"asing Prcedure
&urchasing division is touched with stock levels and reorder levels of each material.
It is assisted to purchase materials before exceeding their minimum stock level.
*hen goods are purchased from new supplier# purchasing division should get the
product specification and quality certificate from supplier. This specification is varied
according to the material.
&.2.1.& $u%%lier Evaluatin
upplier evaluation is done by a panel comprising of 2anaging ,irector# Cuality
Assurance 2anager and incase of raw materials in different divisions relevant
divisional managers through whole year.
4valuation criteria are based on@
&roduct performance
Cuality and $onsistency of the product
&rice
,elivery time
upplier feedback
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&.2.2. 0ruit $tres
:ruit store is responsible for receiving well ripens quality fruits and store the fruits
until it released to the production. taff members of the fruit store are paid special
attention towards quality management while sorting and storing of the receivedfruits. :ollowing procedure is practiced in the fruit storage;
Eeceiving of fruits
election of quality fruits
*eighting
toring of fruits
orting and *ashing
Issued production line
:igure >.!@ :low chart of :ruit tore
2ost probably fruits are stored for about three days. This is depended on fruit
ripening speed and production requirement. efore transferring of fruits in to the
production# fruits are cleaned manually by using three tanks.
&.2.& 0ruit Cutting and Pul%ing $ectin
&.2.&.1 Cutting Area
In cutting section fruit peel# seed and other contaminant are removed and chopped in
to small pieces by using stainless steel knifes. izes of fruit pieces are varied with the
type of fruit.
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&.2.&.2 Pul%ing Area
&ulp machines are used to crush the fruit pieces and extract the fruit pulp. &ulp
machine is included rotating stainless steel bar which is fitted to few brushes. 2etal
net is installed to cover the bar. 2ainly three types of pulp machines are used in pulp
preparation area. These machines are varying according to the sieve size. 7sages of
these machines depend on the type of fruit. There are two outlets# one for pulp# and
another for seeds# peels and wastage. )ime +uice is extracted using the screw mill
machine.
:igure >."@ &ulping machine
&.2.&.2.1 Pul% %reservatin
&repared fruit pulp can be preserved according to two methods.
!. oiling for freeze
*eighted fruit pulp is transferred in to the open steam +acketed pan and
cooked# after reaching boil.
&ulp is poured in to the clean can and transferred in to the freezer.
". Adding preservatives
*eighted fruit pulp is transferred in to the open steam +acketed pan and
cooked# after reaching boiled.
&reservatives and acids are added in to the pulp and poured in to the
clean# sanitized plastic cans.
$ans are weighted and date# batch coded on the can. :illed cans are stored
in ambient temperature ware house.
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Eeceiving of
washing fruits
&eeling $utting
tore in a plastic
crates
Issuing to pulping
section
&ulp from pulp
machine
Issuing to production
area
:igure >.>@ :ruit $utting and &ulping ection
&.2.&.2.2 Cleaning %rcedure ! %ul% -ac"ines
efore use pulping machine# used two types of water to clean.
$hlorinated water
*arm water
After use pulping machine# used this tree types of water to clean.
&ure water
$hlorinated water
*arm water
&.2.5 167-l +lass )ttle 3as"ing and Ins%ectin $ectin
&.2.5.1. 3as"ing $ectin
8lass bottles are checked before sent the washing to ensure bottles are free from;
traw
=eavy worms and eggs
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,amage bottles
7nclear and different shaped bottles
There are mainly two types of washing 2anual washing
2achinery washing
&.2.5.1.1 #ac"iner ,as"ing
Then !/9ml empty glass bottles issued to machine through the conveyer system to
washing. :ollowing methods can observed inside machinery and ottles labels
removed of automatically brush system. =ot *ater bath
=ot $austic oda bath
praying hot $austic oda mixed water
praying warm water
praying cold water
,raining
:igure >.?@ 8lass bottle washing machine
*ashed bottles were checked after washing whether bottles are washed properly#properly removed debris and any particles of bottles and labels.
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4very 9! hour checked quality of washed bottles quality using
phenoptheline. :ew drops of phenoptheline were put into properly washed
bottles and checked colour of it.
&.2.5.1.2 #anual ,as"ing
If bottles contain corrosion and un-removable debrides from the machinery washing
that were sent for the manual washing. 2anual washing contained three washing
tanks.
!st
tank G washing with Teepol
"nd
tank G clean water
>rd
tank G clean water
&.2.5.2 167 -l Ins%ectin $ectin
*ashed bottles again washing by manually used Hohnston taps and high pressure
chlorinated water and checking quality of bottles used frozen light and white
background. Then bottles issued to filling area by conveyer belt.
Eemoved white and dirty bottles# ten issued again bottle washing section.
ottle *ashing
*p
:igure >.@ !/9ml 8lass ottle *ashing and $hecking ection
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!"
&.2.8 0illing Area
&.2.8.1 0illing ! 167 -l glass bttle !ruit drins
:ill using filing machine.
*hen fill bottle immediately sealed by crown caps.
Then passed through steam chamber.
Issued to !/9ml labeling section.
Eeceiving of filled Cuality checking
glass bottle
:igure >.D@ !/9 ml fruit drinks filling
)abeling of
machine
$hecking of
properly
labeling of
&.2.8.2 0illing ! 167 -l glass bttle ,it" -il added drins
7sing filing machine fill.
*hen fill bottle immediately sealed by crown caps.
After that bottles passed through steam chamber and finally send toretorting section for pasteurization.
Eeceiving o
filled milk
glass bottle
Cuarantine
period
)abeling Issued to stores
:igure >.F@ !/9 ml milk added drinks filling
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&.2.8.& 0ruit nectar !illing sectin
5ectar filling section fills drink into different sizes such as "99 ml# 99 ml and !).
*hen receiving the drink from production area its stock in stock tank and then fill
into &4T bottle using filling and sealing machine.
,rink Tunnel tock tank
preparation
$ooling $hecking filled ,rink filling
drink bottles
,rying &lace in
crates
:igure >.0@ :ruit nectar drink filling
&.2.8.5 C"ecing 9ualit ! drin bttles
The quality of drinks bottles were checked after filling fruit and milk added drinks
$hecking this qualities
&roperly fixed lids
)ids damages
&article dirty or debris on bottle
After checking re+ect this bottles.
dirty bottles
half bottles
sample bottles and other bottles
&.2.: abratr
)aboratory is playing important role in the factory by conducting testings and
maintaining natural taste of the drink. 2ainly raw material and product testing are
conducted by laboratory. 2ainly milk and fruit pulp is tested to check the quality and
the suitability of the material for production.
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&.2.:.1 Testing in labratr
$heck p=# acidity# sulphur dioxide level and brix value of every batch of drink
prepared. There are three types of pulps;
:resh pulp
oiled &ulp
$old room pulp
$heck acidity# p=# sulphur dioxide level# brix value and sensory characters of
above mentioned pulps.
$heck the p=# colour# taste# brix# acidity and sulphur dioxide level of final
products.
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*ater
$austic soda
5itric acid
*ater
&.2.;.2.2 Prcess ! Pasteuri'er
&rior to supply of drink circulate hot water.
2iddle of circulation step done back wash.
Aim of pre-rinsing is to remove soils from backwash separate all soil particles
from surface.
After water circulation drink was supply and it heated.
&.2.;.2.& Prcess ! !illing -ac"ine
efore starting of filling there are several steps up to filling stage.
&re heating
Temperature increasing
Tube sealing %:orming of packaging material as tube(
terilization
=ydrogen peroxide spraying %$ontainer is sterilized using chemical sterility as =T.).A? %acage laers
There are seven layers that are shown in below from out to inside;
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$ontinuous
Thermal &rocessing
Incoming &ackaging
$ontinuous
terilization
Ase%tic
$ontinuous 6one
Aseptically :orm :ill
eal
helf G table
&roduct
:igure >./@ Aseptic &rocessing and &ackaging
&.2.@ 3aste 3ater Treat-ent Plant
:actory consumes /9 m> of water per day for processing# boiling floor washing#
equipment cleaning and domestic purposes. All the waste water is accumulated in to
the waste water plant trough trench system. Treated water is released in to the natural
water source.
&[email protected] Prcedure
!. 4qualization tank
4ffluents from all sources are directed in to the equalization tank to equalize the
water by ad+usting p=. $austic soda and hydrochloric acid are used to ad+ust the
water p= up to required level. 4qualized water is pumped in to the anaerobic tank for
further treatments.
". Anaerobic tank
4ffluent is pumped at a constant flow rate from the equalization tank to anaerobic
tank.
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and divided in to several compartments to avoid the short circuiting of the effluent
flow through the tank.
>. Aerobic tank
The over flow from the anaerobic tank is directed to an aerobic tank for further
treatment. Aerators installed inside the tank to provide sufficient aeration for
reducing the
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parameters to check before discharge the treated water to the inland. Table >.".0.! is
shown that parameters and limitation of that.
Table >.! Eequirements for discharge treated water
Para-eter
Total suspended solids %T(
&article size of the T
&=
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&.2.6.1.2 Cleaning ! nce a ,ee
All machineries# equipment and places clean this washing procedure;
7sed normal water
rush with plastic brush pray sanitizer
*ash with high pressure water
pray chlorinated water
&.2.6.1.& Cleaning ! nce a -nt"
:ollow pest control procedure and fumigation process
&.2.17 Healt" and Hgiene %ractices !r ,rers
upervisors check workers health conditions every morning.
Any person who is shown illness or any other abnormal source of microbial
contamination# he or she does not involves in food handling.
Eemove all +ewelry and other ob+ects before entering the factory.
4ating food# chewing gum# drinking beverages or using tobacco is not allowed
within factory.
5ot allowed to touch nose# mouth or hair in the working time.
hort and clean nails to be maintained all ways# and not allowed use nail arts or
cutex.
All ways wear factory uniform# hair caps# masks# apron# gloves and boots before
involving in work.
Immersing your feet with and boots in the foot bath %chorine mixed water(.
Al ways carry out hand washing with sanitizer as a practice.
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&.& Prject ! Industrial training
uggestions were gave for fruit washing system# fruit storing house design# convey
system of processing line as the pro+ect of industrial training after searching
recommended processing lines of the factory. 2otivations of labours positivethinking were done as the part of pro+ect.
uggestion@
5ew washing system design
o nowledge of engineering workshop technology# and food equipment
design fabrication was more helpful to design new washing system
design.
5ew fruit storing house design
o nowledge of cereal science and technology and minimal processing
technology was more helpful to design new fruit storing house.
:or convey system of processing line
o Eepairing and maintaining the convey system in the !/9 ml fruit drink
steam tunnel line and !/9 ml milk added drink steam tunnel line
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CHAPTER 5
CONCUTION AND RECO##ENDATION$
5.1CnclusinIn the industrial training I upgraded my knowledge about following mentioned
categories which are related to the specialized in food engineering.
&reparation of food raw materials and ingredients
torage of raw materials and finish products
:ood process technology
Eesource planning
:ood manufacturing process control
:ood machinery and plant repairing# cleaning# operating
The company has a well-organized management structure which is a great strength
for the future progress of the company. =igh technology involve processing plant# so
it help to maintain the quality standard such as =A$$ ) and I< ""999. Also
there is high demand to produce value added products. It has a well-managed waste
water treatment plan which is another good management practice of the company.
5.2 Rec--endatins and $uggestins
There are several limitations in the organization which were observed during
industrial training period. 2ost of the limitations have very simple solutions and
some may come up with difficulties when executing.
)ack of skillful labor force and lack of positive attitudes labor force
Absence of microbiology and proximate analysis laboratory in the company
*astage of steam
$oncrete floor in the composting tent is damaged and has to repairing time to
time due to low p= in the waste
uggestions;
$onducting the training programs# workshops and team works to build up the
positive attitudes.
4stablishment of microbiology and proximate analysis laboratory.
4stablish the system to collect and condense the steam which are releasing as
waste
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Re!erences
5ational 4nvironment Act 5o. ?F in !/09.
) tandard !"?D@"99>- pecification for $ompost from 2unicipal
solid waste and Agricultural waste.
) tandard for E.T.. %Eeady To erve drinks( G ) F"/.