a project report on quality and safety in soft drink LUMBINI BEVERAGE PVT LTD HAJIPUR

1. An Industrial training on QUALITY CONTROL
LUMBINI BEVERAGE PVT LTD
HAJIPUR BIHAR ,844101
INDIA
PEEYUSH KUMAR
BIOTECHNOLOGY
2011-2015
NIT JALANDHAR

2. Index
• Introduction
• Water treatment process
• Product manufacturing
• Microbial test
• Bottling plant
• House keeping
• Effluent testing
• Safety and quality test

3. INTRODUCTION
PepsiCo is a major producer of carbonated soft drink, other
beverage and snack food .It is sold in stores and restaurant, retail
outlet and through vending machine . Its beverage division
including Pepsi cola drink , water bottles and markets several
popular drink . USA based company PepsiCo acquire Tropicana
and Frito lay .PepsiCo's soft drink products are -
• Pepsi
• Mountain dew
• Marinda
• Lehar Evervess soda
• Slice
• Aquafina
• 7UP

4. 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%

5. • 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 .

6. Testing of treated water
• Total hardness
• Total chlorides
• Turbidity and pH
• Total solids
• Alkalinity

7. 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.

8. 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

9. 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 .

10. 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

11. PREPARATION AND BOTTLING OF SOFT DRINK:
Tank syrup
Cooler
Prepare beverage
Bottling and filling
Packed bottle
CO2 tank

12. 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 .

13. EFFLUENT TREATMENT PLANT
The main aim of effluent treatment is to remove the settle able
solids, floating particles ,oil and grease and also reduce the
biological 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

14. 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 .

15. 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

16. Thank You !!!
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