INTERNSHIP AT COCA COLA INDIA

IN

BRINDAVAN AGRO INDUSTRIES Pvt.

Ltd.

ADD. - NAGLA UMMED, POST - RUHERI, DIST- HATHRAS (UP )

 28 DAYS PROJECT

ON
PLANT LAYOUT & BEVERAGE
MANUFACTURING

Submitted To:- Submitted By :-

Dr. GAJENDRA B. SINGH RAHULBHARTI
Head of Department M.Sc. (BT) 2nd Sem.
Department of Bioscience Inroll. No. 20150816
I. B. M. E. R. I. B. M. E. R.
Mangalayatan University, M. U. Aligarh
Beswan, Aligarh
 Acknowledgement
I would like to take this opportunity to thank all those who
contributed to this report and helped me at every step. I
want to extend my sincere thanks to Mr. Dilip Singh & Mr.
Chandresh Dubey for giving me such a great opportunity to
present this report. I extent my gratitude to Mr. Vinod
Solanki, Mr. Yogesh Upadhyay, Mr. Kshitij Jaju, Mr.
Dheerendra Kumar, Mr. Atul Gupta, Mr. Pawan Kumar, Mr.
D. Pathak, Mr. Pankaj Rawat, Mr. Rajesh Sharma (WTP) &
Mr. Deepak Sharma and all those who helped me with their
valuable support and suggestions. I take immense pleasure
in expressing my utmost gratitude towards everyone who
played a role in my development.
 CONTENTS

1- Introduction
2- History of coca cola
3- Production Process - PET Line
4- CIP (Cleaning-In-Place)
5- Syrup Preparation
6- Water Treatment Plant
7- Reverse Osmosis
 DECLARATION

I hereby declare that I have successfully carried out our one

month Project on the Plant Layout & Beverage
manufacturing at Brindavan Agro Industries Pvt. Ltd.
Ruheri, Hathras (U.P).
I further declare that this report is based on my original
work and no part of this report has been published or
submitted to anybody .

Rahul Bharti
M.Sc. (BT) 2nd semester
Inroll. No.20150816
Department of Bioscience
I. B. M. E. R.
Mangalayatan University
Beswan, Aligarh
 1. INTRODUCTION

A soft drink is a beverage, often carbonated, that does not contain

alcohol. Carbonated soft drinks are more commonly known as soda,
pop, tonic, or soda pop in parts of the United States and Canada, or
fizzy drinks in the U.K.; sometimes called minerals in Ireland.
Beverages like colas, sparkling water, iced tea, lemonade, squash, and
fruit punch are among the most common types of soft drinks, while
hot chocolate, hot tea, coffee, milk, tap water, alcohol, and milkshakes
do not fall into this classification.

Coca-Cola is a carbonated soft drink sold in stores, restaurants and

vending machines in more than 200 countries. It is produced by The
Coca-Cola Company and is often referred to simply as Coke.
 2. History of coca cola

Coca-Cola is the world's largest beverage company , refreshing

consumers more than 50 sparkling and still brands. Led by Coca Cola
one of the world's most valuable and recognizable brand, company's
portfolio feature 16 billion-dollar brands, including Diet Coke, Fanta,
Sprite, Limca, Maaza, vitamin water, Minute maid. The Coca Cola
Company is the No. 1 provider of sparkling beverage, ready to drink
coffee, juice and juice based drinks.

Today Coca Cola is consumed throughout the world at the rate of

more than 600 million times per day and this figure is continuing to
raise. it is the world's largest producer and distributor of syrup and
concentrates for soft drinks . product developed by the company are
sold through bottlers, fountain wholesalers and distributors around
the globe. Brand coca-cola accounts for the about 75% of the
company' sunit sales volume of soft drinks, remaining 25% consist of
well known soft drinks such as Spirit, Fanta, and many other brands.

The Minute Maid company world's leading market of fruit juices.

Use of stimulants in formula

The Primary ingredient of coca cola syrup include either high

fructose corn syrup and sucrose derived from the cane sugar, caramel
color, caffeine, coca extract, lime extract, vanilla, and glycerin.
However, contrary to what is implied by the "cola" name, coca-cola
syrup does not contain any kola nut extract. Since no kola extract are
present in the reciep, the primary taste of coca-cola comes from
Vanlla and Cnnamon with trace amount of orange, lme, and

lemon and spces such as Nutmeg.

Coca - Cocaine
Coca leaves were used in the Coca-Cola's preparation and the small
amount of Cocane present in the product gave the drinker a "buzz."

Franchised production model

The actual production and distribution of Coca-Cola follows a
franchising model. The Coca-Cola Company only produces a syrup
concentrate, which it sells to various bottlers throughout the world
who hold Coca-Cola franchises for one or more geographical areas.
The bottlers produce the final drink by mixing the syrup with filtered
water and sugar (or artificial sweeteners) and then carbonate it
before filling it into cans and bottles, which the bottlers then sell and
distribute to retail stores, vending machines, restaurants and food
service distributors.
 3. PRODUCTION PROCESS

Production continues in two different sections. These sections are on

the basis of type of bottles.

A. PET Bottling
B. RGB Bottling

PET bottles are formed from the preforms of the material Poly
Ethylene Terepthalate.

RGB are known as Returnable Glass Bottles. These empty bottles are
returned from the market and reused after processing.

(Here are only PET LINE Process)

PET LINE

In PET line, PET bottles are made from performs which are
tested before use.
In perform testing, height, weight, polarization are checked
according to coca cola India standards.
*For 600 ml (Weight = 25.7 gm., Height = 96.78 gm.)
*For 1.25 Lt (Weight = 37.7 gm., Height = 126.7 gm.)
*For 2 Lt. (Weight = 46.7 gm., Height = 145 gm.)

PET Blowng process & fllng of PET bottle Flow

 chart:-

preform issue from store

transfer of preform from store to blowing room

preform storage in blowing room or day storage

preform uploading in the hopper by the preform

filter from jumbu carton

preform through the elevator

preform convey through conveyor

Heating of Preform

Blowing Machine (SIPA)[air pressure= 40n bars, temp.=

90-110C]

Checking Blown Bottle Specification

 Air Flow through Air filter

Conveyed to filler

Rinsing with 1-3 ppm Cl2 in soft water &
pressure=1.5kg/cm

Through this process PET bottles will be ready for the filling
of beverage . but some defects can be occure in the PET
blowing process

these are the some defects :

1. Deformed Neck :
cause- excessive temp. in the zone under the neck
solution - reduce the temp.
2. Excessive material on the base :
cause- law temp. in the zone
delay in the preblowing
solution- increase the temp.
earlier the preblow
3. Folded Neck :
cause- wrong profile in the oven late preblowing
 solution- earlier the preblowing

Filling process :-
Treated water intake in deareation tank

syrup intake in the syrup tank of paramix

mix inline through V-10 proportioning value

beverage for chilling through PHE

injection of CO2

beverage in the buffer tank

proportioning of treated water, syrup & CO2
(chilling , carbonating , mixing temp.= 7C )

counter pressure filler

filling

closure -- elevator closure -- capping of filled bottle

checking of filled bottle torque (5-17Psi)

warmer temp. [ 38 - 42C]

labelling

data loading

filled bottle inspection -- removal of half filled and defect
bottle

|

corrugated pad -- shrink wrapping [ temp. 150-160C]

secondary coading on HDPE layer

storage of finished product

Dispatch

4. CIP (Cleaning-In-Place)
It is the method of cleaning the interior surface of pipes and
other process equipment, filters without disassembly.
There are the 2 type of CIP process
3- step process
5- step process

1. 3- Step process :-
Rinse the equipment with treat water ( time= 10 min.)
- after 5 min.
wash with the hot water (temp.= 80-90C, time= 15
min.)
- after 5 min.
wash with the cold water (time= 10 min.)
Total time : 45 minutes +/- 5 min.

2. 5- Step process :-
Rinse the equipment with the treated water ( time= 10
min.)
- after 5 min.
wash with the caustic soda(1-1.5%,temp. 60-70C, time= 15
min.)
- after 5 min.
wash with the treated water( time= 10 min.)
 - after 5 min.
wash with the hot water (temp.= 80-90C, time= 15 min.
- after 5 min.
wash with the treated water( time= 10 min.)
Total time : 80 minutes +/- 5min.

CIP for the different flavour from one to another:-

* NOTE:
3S - 3 step
5S - 5 step
SP - same process
F - flusing with the treated water for 10 min.

5. SYRUP PREPARATION:

Hot treated water [T= 60-70C]

weighing of sugar& dumpng in to the tank
[water=55% of sugar taken( Fanta) , 60% for
other valuable brand (coke, T/UP,
sprite, Limca) ]
- mix. carbon & Decalite (0.3% of
sugar)
Heated upto 85C

Hold as such for 30 min. with agitation

 filter press dressed

recirculation of the syrup if the syrup is not clear

cooling of syrup at 10-30C

transfer of syrup in to ready syrup tank

transfer liquid and conc. part in to readt syrup tank --
mixing of concentrate in to tank

make up standard brix and volume as per MMI by
addition of treated water

Deareation and storage at 10-30C

Here the list of the components that used in the syrup

prepration .

PHE
Filter Press
Storage tanks
Pipelines
 Gauges (Temperature , Pressure)
Sugar
Water
Beverage base in two parts

Part1=phosphoric acid, natural colour,caffeine,water.

Part2=water, natural colors, added flavours

6. WATER TREATMENT PLANT (WTP):-

A. Soft water manufacturing

Source of water(Borewell 1 & 2)
- add Cl2 (3-5 ppm)
Raw water storage tank

PSF filtration

ACF Filtration

Softner
-------------------------------------

Non chlorinated water soft water storage tank
 (1-3 ppm Cl2)
Utility
Resin filter (Decrease the
hardness)

Hardness <10 ppm PET
rinser
Key :-
PSF : Pressurized Sand Filtration
ACF : Activated Carbon Filtration
LLACF : Lead & Lag Activated Carbon Filtration
OPRP : Operational Pre-Requisite Program
CCP : Critical Control Point
Cl2 addition in form of Calcium Hypochlorite(65% purity).
Recovery Rate= (Product Flow/Feed Flow)*100
Differential Pressure= Feed Pressure - Reject Pressure
B. Treated water manufacturing:-
source water- borewell
- Cl2 addition
raw storage water

 PSF filtration

ACF filtration

7. Reverse osmoss process

treated water storage
- 3-5 ppm Cl2
ACF filtration

LLACF filtration

5- micron filtration

UV filtration
-------------------------------------------------------------

CIP proportioning syrup
room
 TESTING :-
1) BRIX soluble solids expressed as weight % of pure
sucrose in water.
a. Dry the meter.
b. Flush the syrup 2-3 times through it till air is completely
removed.
c. Press START- wait & observe the readings.
Formula: (Inverted Ready Syrup BRIX/Standard Ready Syrup
BRIX)=X
X*Standard Beverage BRIX = Target BRIX

2) GAS VOLUME times of CO2 dissolved per 100ml of

beverage.
a. Collect the bottle from line
b. Clamp it
c. Press piercing device downward
d. Shake
e. Open snift valve
f. Remove clamp assembly & discard the bottle
g. Measure its temperature
h. Get GV by Pressure vs. Temperature chart.
3) CO2 flow setting
a. for Beverage: Beverage flow*GV*1.4
b. for Soda: Water flow*GV*1.98
4) CO2 Taste/Appearance test-
Treated water: 400ml + Sugar added: 20g + Citric acid: 16ml
Divide into two parts.
Part 1- Pass CO2 for 15minutes.Observe.
Part 2-Taste & compare with other part.
5) Torque Test-
a. Place the PET bottle over torque weighing machine
b. Hold the cap
c. Rotated to the left to maximum possible
d. Note the bottle
e. Rotated to the right to maximum possible
f. Note the value.
6) Bottle Burst Crack Test-
a. Place the bottle within burst tester
b. Ensure that bottle is filled with water
c. Switch ON to pass CO2 gas through the bottle
d. If bottle can bear CO2 pressure- Test OK
e. Otherwise test fails.
7) Brimful Capacity-
a. Note the temperature of beverage in bottle B
b. Find out the density using Temperature vs density(d) chart
c. Apply the formula
B: Bottle filled with beverage upto a specific level
A: empty PET bottle
Then Brimful Capacity = (B-A)/d
8) Caustic Carry Over Test-
a. Collect the bottle from/after washer
b. Added 3-4 drops Phenolphthalein indicator
c. If pink color appears then add 25ml distilled water
d. If still pink color is visible i.e. caustic traces are present
e. Stop the washer- take necessary measures.
9) Caustic concentration in container washer-
a. Detergent solution:10ml
b. Phenolphthalein indicator : 2-3ml
c. Titrated against 1N H2SO4
d. VolumeH2SO4 used = P-value noted
e. Added 2-3 drops of (M)Methyl purple indicator
f. Green coloration
g. Titrated against 1NH2SO4& its volume is noted
h. End point: Grayish purple.
[NaOH] = (2P-M)*0.4
10)Net Content Testing-
X-Bottle weight with crown & beverage
Y-Empty bottle weight
Z-Weight of CO2 = Target GV*1.98*Pack size in litres
then Net Content = X Y Z
11)Date Code Durability Tests-
a. Visual Test
b. Rub Resistant Test
c. Ice Water Immersion Test
d. Refrigeration Test
e. Ageing Test
 WTP TESTING:
1) Taste/ Odour /Appearance
2)P-Alkalinity-
a.100ml of water sample is taken
b.2-3 drops of Phenolphthalein Indicator is added
c.Titrated against 0.02N H2SO4
d.Colour change : pink to colorless
e.Volume of Sulphuric acid used is noted
3) M-Alkalinity-
a. 100ml of water sample is taken
b. 2-3 drops of Methyl-Orange is added
c. Titrated against 0.02N H2SO4
d. End Point : orange to pale red
e. Volume of Sulphuric acid used is noted.
4) Total Hardness-
a. 100ml of water sample is taken
b. One T.H tablet is added to it
c. Then 5-6 drops of Ammonia buffer is added
d. Titrated against 0.02N EDTA solution
e .End point: pink to blue/violet
f. Volume of EDTA used is noted.
Formula:- (Volume of EDTA or H2SO4 used*1000/Volume of
water taken initially) = value in ppm
5)Chlorine concentration in ppm -
0.1N Na2S2O3 (Sodium Thiosulphate) is taken in burette
100ml of water sample is taken in flask
Potassium Iodide (15ml) is added to it
Then 2-3 drops of starch solution indicator is added
End Point : blue to colorless
Final reading of Sodium Thiosulphate is noted
cl2 (ppm)= (Burette Reading*35.5)/10
6) Preparing chlorine solution
Stock solution (ppm) = (Water quantity*Required
ppm)/Purity of chlorine

BIBLIOGRAPHY
The information about the company is obtained via website:

www.cocacolaindia.com

www.thecoca-colacompany.com