TRANSFORMATION PROCESS

BISLERI INTERNATIONAL PVT.LTD

By : Swati Manohar (D 13)

Minu Sah (D14)

1

Table Of Content

Sr.No Particulars

1. Objectives Of the Project

2. About the Industry

3. About Bisleri

4. Transformation Process in general

5. Departments in M/s Parle Bisleri Pvt. Ltd.

6. Production System Model

7. Production Process

8. Planning for production function

9. ABC Analysis

10. Conclusion

2

Objectives of the project

1. The project will illustrate the working of different departments in production process.2. With the help of this project we would come to know different stages of production or

transformation process. It will focus on conversion of input into output.

3. The project gives us an understanding of types of machines used while production in Bisleri.

3

About the Industry

Corporate control over water and water distribution in India is growing rapidly: the packaged

water business is worth Rs 1,000 crore, and it's growing at a huge 40-50% annually. Around

1,200 bottling plants and 100 brands of packaged water across the country are battling over the

market, overdrawing groundwater. Bottled water, one of India's fastest-growing industries, is a

business built on the foundation of bad governance, inequity and exploitation. It is Hard to

believe, but its true. Around 1.2 billion people worldwide lack access to clean drinking water.

Today, there are more people in the world's hospitals suffering from waterborne diseases than

any other ailment.. Providing safe drinking water is the responsibility of the state. That they are

failing miserably is evident from the fact that over 1,600 Indians reportedly die every day

because of waterborne diseases. Despite these astounding figures, the Indian state has literally

washed its hands of the responsibility of providing clean drinking water to its citizens.

Multinational corporations would have us believe so. And the reason is not hard to find: along

with imported water treatment technology like activated carbon and ultra violet (UV)

disinfection (Aquaguard), reverse osmosis (Reviva) and resins (Zero-B), the water treatment

market is estimated to be worth around Rs 700 crore. According to the Bureau of Indian

Standards, there are 1,200 bottled water factories all over India (of which 600 are in the state of

Tamil Nadu). Corporate control over water and water distribution in India is rapidly growing. As

globalisation opens up opportunities for private players, investing in water and/or manipulating

water scarcity makes increasingly good business sense for corporations.

4

About Bisleri

Mineral Water under the name 'Bisleri' was first introduced in Mumbai in glass bottles in two

varieties - bubbly & still in 1965 by Bisleri Ltd., a company of Italian origin. This company was

started by Signor Felice Bisleri who first brought the idea of selling bottled water in India.

Parle bought over Bisleri (India) Ltd. In 1969 & started bottling Mineral water in glass bottles

under the brand name 'Bisleri'. Later Parle switched over to PVC non-returnable bottles & finally

advanced to PET containers.

Presently bisleri has 8 plants & 11 franchisees all over India. Commanding a 60% market share

of the organized market. Overwhelming popularity of 'Bisleri' & the fact that it has pioneered

bottled water in India, has made it synonymous to Mineral water & a household name. When you

think of bottled water, you think Bisleri.

Bisleri has developed 8 unique pack sizes to suit the need of every individual. They at present

5

have 50ml cups, 250ml bottles, 500ml, 1L, 1.5L, 2L which are the non-returnable packs & 5L,

20L which are the returnable packs.

Bisleri Water is put through multiple stages of purification, ozonised & finally packed for

consumption. Rigorous R&D & quality controls has made us a market leader in the bottled water

segment. Strict hygiene conditions are maintained in all plants.

6

Transformation processes

A transformation process is any activity or group of activities that takes one or more inputs, transforms

and adds value to them, and provides outputs for customers or clients. Where the inputs are raw

materials, it is relatively easy to identify the transformation involved, as when milk is transformed into

cheese and butter. Where the inputs are information or people, the nature of the transformation may

be less obvious. For example, a hospital transforms ill patients (the input) into healthy patients (the

output).

Transformation processes include:

changes in the physical characteristics of materials or customers

changes in the location of materials, information or customers

changes in the ownership of materials or information

storage or accommodation of materials, information or customers

changes in the purpose or form of information

changes in the physiological or psychological state of customers.

Often all three types of input – materials, information and customers – are transformed by the same

organisation. For example, withdrawing money from a bank account involves information about the

customer's account, materials such as cheques and currency, and the customer. Treating a patient in

hospital involves not only the ‘customer's’ state of health, but also any materials used in treatment

and information about the patient.

One useful way of categorising different types of transformation is into:

manufacture – the physical creation of products (for example cars)

transport – the movement of materials or customers (for example a taxi service)

supply – change in ownership of goods (for example in retailing)

service – the treatment of customers or the storage of materials (for example hospital

wards, warehouses).

7

Several different transformations are usually required to produce a good or service. The overall

transformation can be described as the macro operation, and the more detailed transformations within

this macro operation as micro operations.

Departments in Parle Bisleri Pvt. Ltd.

“Parle Bisleri Pvt. Ltd.” It is a medium scale company and it manufactures and sells

“Packaged Drinking Water” The different departments of this company are: -

1.Filler Department : -

This is the plant in which the bottles are filled and packed under strict levels of hygiene and

safety as per the EU norms.

8

INPUTS OUTPUTS

THE

TRANSFORMATION

PROCESS

Customer Feedback

Performance Information

2.Plastics Department : -

Caps Section

Preforms Section

This is the Department where pet material is processed to make preforms using 6 Ekou

injection moulding machine of 180 and 330 tonnes as per the requirements of the preform.

Preforms are available in various sizes according to the size of bottle.

Bottle Sizes Preform Sizes

1 ltr 21gms

500 ml 17gms

250 ml 15gms

1.5 ltr 32 gms

2 ltr 34 gms

5 ltr 75 gms

20 ltr 710 gms

Caps are made from a mixture of HDPE and LLDPE using 4 Cincinnati Milacron and 2 Windsor

injection-moulding machines.

9

3.Water Treatment Plant : -

Over here the Raw water from the bore wells is treated in several stages before it is filled thus

making it very pure for human use.

4.Blowing Department : -

Over here the preforms are blown into bottles. This department has various manual and fully

automatic stretch blow moulding machines.

5. Water Testing Laboratory : -

The water-testing lab ensures that the water safety standards are maintained as per the BIS and

EU norms.

6. HORAI Department (Grinding Department): -

All rejected bottles, caps, jars and lumps of plastic material are sent over here for grinding in

order to re-use it. Before it can be grinded it is very carefully segregated in different groups.

They also buy plastic bottles from outside and grind them for resale. It is a fully automatic plant

7. Stores Department : -

All the stock of finished, semi-finished goods are stored over here and are dispatched as per the

orders. Up to 50 tonnes of stock are dispatched in a day.

10

11

INPUTS CONVERSION SUBSYSTEM

OUTPUT

Environment

Legal FDA, BIS, BMCTechnological

automatic inj. Mldg. m/c, auto blow mldg. m/c.

Market

Competition with Aquafina, Kinley etc.Customer Desire50 m.l., 100 m.l., 25 litres and low price

Primary Resources

Material: -

Water from bore wells HDPE, LLDPE, PET.

Personnel: -

Plastics Engineering, Production Managers.

Capital Assets: -

Auto Filling Machine, Blow moulding machine, recycling machine

Physical

Manufacturing

Locational Services

Transportation

Exchange

ServicesWholesalerRefill

Other Private Services

Utility

Bisleri Bottles

Control Subsystem

Sealed bottle, FDA, Quality Control

Production System Model

Inputs

Environment

1) Legal : -

Parle Bisleri being a company involved in selling water which is fit for consumption it

2) Technological: -

comes under the FDA, it also follows the standards of BIS. Therefore ensuring its quality

and the public perceive the right image of being 100% safe.

Parle Bisleri believes in keeping up with times and they are trying constantly to increase their

share market. This is the reason Bisleri has automatic Injection Moulding Machine in order

to increase their production capacity 3 folds. Bisleri already has 2 automatic Blow Moulding

Machines.

Market

1) Competition : -

Parle Bisleri Pvt. Ltd. 1992 at that time Bisleri enjoyed almost a complete monopoly.

Recently however, companies like Pepsi and Coco cola have entered the market to give

tough competition to Bisleri by introducing brands like kinley and Aquafina.

2) Customer desire :-

Bisleri has become a household name to the extent that people instead of calling it packaged

water are calling it Bisleri.

-

12

Primary resources: -

1) Material : -

The raw water is obtained from bore wells. The bottles are made from polymers such as

HDPE, LLDPE and PET.

2) Personnel : -

Bisleri requires mostly skilled and semi skilled labourers. The skilled labourers include

production and plastic engineers.

3) Capital assets : -

Bisleri has got 14 injection moulding machines, 2 automatic blow moulding machines and 4

semi automatic blow moulding machines. It has also got 2 plants located side by side for

production purposes.

Conversion Subsystem

1) Physical : -

Parle Bisleri Pvt. Ltd is considered to be a manufacturing unit as it manufactures the semi

finished product i.e. bottles and caps and also produces the finished products.

2) Exchange services : -

The distribution network of Bisleri is maintained by its distributors and wholesalers. To

supply to big corporates they have their own distribution network.

3) Outputs : -

The final output of whole manufacturing process is we get clean pure drinking water in

bottles of different sizes according to the needs of the consumers.

13

Quality control subsystem

The motto of Bisleri is “play safe” and Bisleri has implemented every measure to produce the

safest product possible. It has employed measures such as:-

1) The quality of every single raw material that goes into the products are minutely

inspected in order to ensure optimum quality standards.

2) The caps of all the bottles are tamper proof so when the consumer buys a Bisleri product

he ensures that the product is untampered.

3) The production process of Bisleri is such that a human hand never touches a Bisleri

product.

4) There is 24 hours quality checking so that no defective product reaches the consumer.

14

Production Process

1) The raw material (HDPE, LLDPE, PET) that is stored in the warehouses is transported to the

processing plant near by.

2) In the cap department where caps are produced. HDPE and LLDPE which are in the form of

granules are emptied into the hopper of the injection moulding machine with a colorant and

the caps are produced of the characteristics green colour of Bisleri. The caps that are

produced are automatically packed into cartons. This semi finished product is transported,

after quality testing has been done, to what is called the filling department. In the caps

department there are 7 injection moulding machines

3) In the preforms department which is located in next to the cap department it is located in the

same plant. In the preforms department PET material is used to manufacture preforms which

are semi finished bottles. They are produced by using injection moulding machine. After the

preforms are tested by the quality assurance department, they are packed in cartons and

transported to the filling department. In the preforms department there are 7 injection

moulding machines

15

4) In the blowing department the preforms which are obtained from the preforms department

are blown to form bottles. There are a total of 2 fully automatic blowing machines which are

directly connected from to the filler. There are about 5 more semi automatic and automatic

blowing machines which are producing bottles everyday.

5) The filling department is situated in a closed and a controlled environment to maintain the

hygiene. The bottles are transported from one operation to another on conveyor belt. The

bottles are directly loaded onto the conveyor belt, first bottles passed through UV light to

kill the bacteria, then the bottles are cleaned by pure water, then the bottles are filled to the

desired quantity and then they are automatically capped, then the sticker is put on the bottles

and the price, manufacturing date, batch number are printed by spraying machine on the

bottle itself, then the bottles pass through a screen of white light where workers manually

check all the bottles for any defects, lastly they are packed in cartons and stored in the

warehouse ready for transportation to its destination.

16

6) All the waste bottles are separated and they collected and send to the recycling department

for recycling where they are cleaned, grinded to a coarse powder which is again used in the

manufacturing process thus reducing wastages and being environmentally friendly. This

plant is also used for recycling of outside PET bottles and thus earning extra revenue.

7) In the water treatment plant the water form the 8 bore wells are stored in the Chlorinated

Raw Water Tank (CRWT), the chlorine in this tank is used to kill the germs, after that the

water goes through the sand filter where the solid wastes are removed, after this the water

passes through the carbon filter to remove the foul odour, then the water passes through the

Ultra Violet Light Chamber where the Water passes through it to cure the bacteria and

viruses, then the water passes through a reverse osmosis process to remove the dead

membranes of bacteria and viruses, then the water is passes through the silverisation

chamber to give the sparkle to the water, then the water passes through the ozonisation

process to remove the chlorine and to remove the and its stale odour.`

17

Water Purification Process of Parle Bisleri Pvt. Ltd.

Planning for production function

1) Material

Without materials there can be no output. Material input may account for as much as 80%

of the value of the output. This fact indicates the importance to be attached to material

purchasing.

The materials required for the production process of packaged drinking water are: -

A) Raw water

B) HDPE

C) LLDPE

18

Raw Water

Sand Filter

Chlorinated Raw Water Tank

Carbon Filter

U.V. Filter Reverse Osmosis

Silverisation Ozonisation

D) PET

E) Recycled PET granules

F) Cartons

G) Stickers

2) Methods

This function analyses possible methods of manufacture and tries to define the best method

compatible with a given set of circumstances and facilities.

The method for producing packaged drinking water starts with the production of bottles

and caps. After that the semi finished products are transported from the cap and performs

division to the filling division where the caps are added to the filling machines and the

preforms to the corresponding size of the bottle, these bottles are then added to the

conveyor belt to complete the process of filling the bottle automatically. After the bottle is

filled to the desired level the bottle is automatically capped and then sticker is put on the

bottle the price is printed through a spray gun. Then it is visually inspected and after that

put into cartons readily for delivery.

3) Machines and Equipment

Industrial production is closely related to available production facilities coupled with

appropriate machine and equipments. Considerations:

1) Equipments can be purchased fresh or second hand

2) Equipment can be lease or rented

3) Equipment can be fabricated within the plant

Machines used in Bisleri are injection moulding machines for the production of preforms

and caps. For making bottles blow moulding machines are used to blow the bottles to the

19

required size and shape of the bottles by the use of moulds. Automatic fillers are employed

for the purpose for clean and efficient filling of the bottles with the least amount of

rejection.

4) Routing

The determination of where each operation on a component part, subassembly or assembly

is to be performed results in a route for the movement of a manufacturing lot through the

factory.

The route of the production process is designed in such a way that in process transportation

is at a minimum. The plant layout is in such a way that it is easy to transport the semi-

finished product. First comes the semi finished product then it is blown filled and sealed,

now ready for delivery.

5) Estimating

. Estimating is a special type of forecasting.

Bisleri being an old company has being estimate the demand for its production due to its

past experience it is able to estimate the demand. As a general rule the demand for Bisleri

is very less but the production of Bisleri continues as the demand in summer is so high that

the production cannot keep pace with the production requirement. They also take help of

market surveys and past trends to determine the production requirements.

6) Loading and Scheduling: -

Both scheduling and loading help in production planning. Scheduling refers to the

preparation of a time table for various operations covering the beginning and finishing

20

times of various operations. Loading refers to the time gap for various work loads booked

in advance for different products. Thus scheduling guarantees the observation of delivery

times and loading guarantees the maximum utilisation of the available facilities.

According to the schedule of the delivery and amount to be delivered and where they are to

be delivered the trucks are loaded to be sent to wholesalers and retailers

7) Dispatching: -

Dispatching refers to the actual issuing of orders for performing operations in different

sections or units. It involves the following steps:

1) To make raw materials, equipments, tools and machines available to the worker

2) To issue orders and instructions in writing about the method of work and time for

completion

3) To note start and finish time of each process

4) To evaluate the performance and progress of production schedule

5) To introduce suitable changes in schedules

Distribution of the bottles is done using trucks of different sizes if the deliver has to be

done in the city the smaller trucks are used which are of Eicher. If the delivery has to be

made outstation then the larger Tata Trucks are used. The normal distribution to the

distributors within the city the delivery takes place 7:00 a.m. every morning except Sunday.

8) Follow Up: -

The effectiveness of any production control system is dependent upon timely and adequate

information regarding actual performance. This information usually originates with the

dispatcher..

21

After the delivery has been made the marketing people visit the retailer, wholesalers,

distributors for their complaints if any written and left for the consideration of their

superiors.

9) Inspection: -

Inspection is an integral aspect of quality control programme. It helps in maintaining and

raising the quality of products. Inspection judges production against established standards.

There is a very efficient quality control process followed by Parle Bisleri Pvt. Ltd. it

inspects everything from the water to the bottles very regularly, in fact it is one the main

issues in quality control of the company. The first thing the quality control head does is to

check the previous days rejection and to finds its individual reasons of rejection and steps if

required.

10) Evaluating: -

Evaluating is the important link between control and future planning. Evaluating function

provides a feedback mechanism on a longer term basis so that past experience can be

evaluated with a view to improve use of methods and facilities.

Operations of Parle Bisleri are inspected by FDA (food and drug associations) Bisleri also

follows BIS (Board of Indian Standards).

11) Laboratory Testing : -

Every hour samples of water that are filled in to the bottles are taken and various testing is done. First it is checked for odor if any, presence of alkanity, chlorine and calcium. The water is also checked in machines like PH METER, TDS(TOTAL DISSLOVE SOLIDS) METER, NEPHLOMETER, SPECTROPHOTOMETER AND MEASURING OF TUBILITY. They also do aerobic  microbial count and pathogen testing.

22

Conclusion

In conclusion it can be inferred that production management is very important in today’s

competitive world where cost cutting is a norm rather than exception. Production management

provides a science for effective profit maximization and optimum resources utilization.

Bisleri who ahs been in the past been facing tough competition from the other brands has

adopted production management in a big way in order to maintain its lead in the packaged

drinking water market.

By this project we have tried to highlight some of the measure taken by Bisleri in order to

improve its production processes and to show the significance and the benefits of production

management in today’s globalised market

23