Transcript
8/4/2019 Aarti IV Bisleri Project
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Project Report on Industrial Visit
For
Bisleri
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Details of Visit
Name of the Company : Parle Product Pvt. Ltd.
Date of visit :
Duration of Visit :
Address :
Product Manufactured : Mineral water
Name/Designation :
of the Concerned
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Index
Sr.No Contents Page
No.
1 Introduction
About Company
Products & Services
Plant Layout
6-7
7-9
10
2 Manufacturing Process
Input
Process
Output
11-13
14-17
18
3 Observation /Suggestions 19
4 Opinion about Industrial Visit 20
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1. INTRODUCTION
Introduction to 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.
Since 1995 Mr. Ramesh J. Chauhan has started expanding Bisleri operations substantially and
the turnover has multiplied more than 20 times over a period of 10 years and the average growth
rate has been around 40% over this period. Presently Bisleri has 8 plants & 11 franchisees all
over India. Their presence covers the entire span of India. Bisleri commands a 65% market share
of the organized market.
Bisleri value their customers & therefore have developed 8 unique pack sizes to suit the need of
every individual. Bisleri is present in 250ml cups, 250ml bottles, 500ml, 1L, 1.5L, 2L which are
the non-returnable packs & 5L, 20L which are the returnable packs. Till date the Indianconsumer has been offered Bisleri water, however in effort to bring new refreshingly, Bisleri has
introduced Natural Mountain Water - water brought from the foothills of the mountains situated
in Himachal Pradesh. Hence Bisleri product range comprises of two variants: Bisleri with added
minerals and Bisleri mountain water.
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Products
Mainly the Bisleri product range comprises of two variants:
1. Bisleri with added minerals
2. Bisleri mountain water.
1. Bisleri with added minerals
Bisleri Mineral Water contains minerals such as magnesium sulphate and potassium bicarbonate
which are essential minerals for healthy living. The not only maintain the ph balance of the body
but also help in keeping human body fit and energetic at all times.
Bisleri with added minerals is also put through multiple stages of purification to ensure the
elimination of all forms of bacteria. This makes the water to drink completely safe to consume.
Bisleri with added minerals is available in 250ml cups, 250ml bottles, 500ml bottles, 1L bottles,
1.5L bottles, 2L bottles and 5 and 20L cans.
2. Bisleri mountain water
Bisleri Natural Mountain emanates from a natural spring, located in Uttaranchal and Himachal
nestled in the vast Shivalik Mountain ranges. Lauded as today's 'fountain of youth', Bisleri
Natural Mountain Water resonates with the energy and vibrancy capable of taking you back to
nature. Bisleri Natural Water is bottled in its two plants in Uttaranchal and Himachal Pradesh.
and is available in six different pack sizes of 250ml, 500ml, 1L, 1.5L, 2L and 5L.
The water that almost descends from the Gods:
Vedica Natural Mountain Water comes to in all its untouched purity, right from its source.
Gushing from an aquifer with intense pressure, the natural mountain water is pushed above theground surface to a height of 5 meters above ground level, powerfully and consistently. The
underground geological origin guarantees that there is no external Contamination, since the
mouth of the water source is covered from rocks on all sides. Besides, being naturally fortified
with silica, the spring is naturally free form any Microbial infection or pollution. Vedica Natural
Mountain Water is also low on sodium, making it the perfect choice for the health conscious. It
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has a high proportion of sulphates, which work as natural detoxifying agents. And it’s clear,
sweet taste proves that it is free of calcium carbonate and magnesium carbonate salts, which give
some mineral waters a chalky taste. Scientifically put, the Total Dissolved Solids in Vedica
Natural Mountain Water is225mg/ltr. It is also high in sulphates, the natural detoxifying agents.
Ensuring that all you get with Vedica Natural Mountain Water is the sweet taste of purity.
Bisleri new Vedica is the most alkaline water there is. Vedica pH is 7.7, Himalayan pH is 7.3 &
Evian pH is 7.2. The benefits of the alkaline lifestyle, alkaline water helps to neutralize acids
and remove toxins from the body - it is a great cleanser and helps to detoxify our system.
Comparative study of Chemical Parameters of Vedica, Himalayan, Evian and Volvic
SR. NO. PARAMETER BISLERI VEDICA HIMALYAN EVIAN
1 PH 7.7 7.3 7.2
2 TDS at 180 deg.C (ppm) 225 330 309
3 Calcium (ppm) 47 62 78
4 Chlorides (ppm) 13 8 4.5
5 Bicarbonates (ppm) 201 63 357
6 Sulphate (ppm) 19 _ 10
7 Magnesium (ppm) 13 15 24
8 Sodium (ppm) 14 20 5
Table 1: Comparative study of Chemical Parameters
Source: www.Bisleri.com
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PLANT LAYOUT
FIG 1: PLANT LAYOUT
Samant Road
Security
Cabin
Garden
G
Laboratory Stocking and
Storage of the
Finished Products
i.e., 500ml, 1Litre,
20 Liters Bottles
Disinfection of the
20 Liters Jars
Blowing
Wing
Filling Wing Capping Wing
Western
Express
Highway
Main
EntranceDispatching Vehicles Space
Administration Office
Bore well Water Treatment
Plant
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2. Manufacturing Process
INPUT
Raw materialWithout 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 main input for Bisleri is the raw water, the raw water is obtained from the 8 bore well which
are situated in the plant.
The other materials required for the making of plastic bottles are polymer such as HDPE,
LLDPE, PET, Recycled PET granules. Cartoons and Stickers are also required for the
packing and labeling of the bottle.
HPDE (High-density polyethylene)
High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a polyethylenethermoplastic made from petroleum. It takes 1.75 kilograms of petroleum (in terms of energy and
raw materials) to make one kilogram of HDPE. HDPE is commonly recycled, and has the
number "2" as its recycling symbol. HDPE contains the chemical elements carbon and hydrogen.
LLDPE (Linear low-density polyethylene)
Linear low-density polyethylene (LLDPE) is a substantially linear polymer (polyethylene),
with significant numbers of short branches, commonly made by copolymerization of ethylene
with longer-chain olefins. Linear low-density polyethylene differs structurally from conventional
low-density polyethylene because of the absence of long chain branching. It has good resistance
to chemicals and to ultraviolet radiation. It has good electrical properties.
PET (Polyethylene terephthalate)
Polyethylene terephthalate (sometimes written poly(ethylene terephthalate)), commonlyabbreviated PET, PETE, or the obsolete PETP or PET-P, is a thermoplastic polymer resin of the
polyester family and is used in synthetic fibers; beverage, food and other liquid containers;
thermoforming applications; and engineering resins often in combination with glass fiber.
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Man
Bisleri requires mostly skilled and semi skilled labourers. The skilled labourers include
production and plastic engineers.
Machine
Injection moulding machine:
Injection moulding machines for the production of pre-forms and caps.
Blowing machines
The Blowing machines for the production of bottles from the pre-form.
Automatic fillers
For the purpose cleaning and efficient filling of the bottles with least amount of rejection.
Assembly line
Assembly line is used for the checking and removing the rejected bottles or damage
bottles
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PROCESS
1. Water treatment process:
Every drop of Bisleri water is purified as per international standards to ensure that Bisleri
experience always remains pure and satisfying for longer. The following is a brief understanding
of the water treatment process:
FIG 2: Water treatment process diagram
I. Ground water: The Raw water is the Water taken from the 8 bore wells present at the
Plant.
II. Ozonisation: Ensures water remains bacteria free for longer life.
III. Pre-filtration: After ozonisation water goes through the Sand Filter where the solid
wastes are removed. The Carbon Filter removes residual chlorine & odours.The
Ultraviolet chamber helps to cure the bacteria and viruses present in water.
IV. Reverse osmosis: Reverse osmosis is similar to the membrane filtration treatment
process RO (Reverse Osmosis), however involves a diffusive mechanism so that
separation efficiency is dependent on influent solute concentration, pressure and water
flux rate .It works by using pressure to force a solution through a membrane, retaining the
OZONISATION GROUND WATER PRE-FILTRATION
REVERSEOSMOSIS
MICRONFILTRATION
ADDEDMINERALS
FINAL
OZONISATIONN
FINAL PRODUCT
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solute on one side and allowing the pure solvent to pass to the other side. This is the
reverse of the normal osmosis process, which is the natural movement of solvent from an
area of low solute concentration, through a membrane, to an area of high solute
concentration when no external pressure is applied. Reverse osmosis removes organic
material. Controls total dissolved solids in the water.
V. Micron filtration: additional safety measures to guarantee purity.
VI. Added minerals: after the micron filtration the minerals such as magnesium sulphate and
potassium bicarbonate are added in to the water, which are essential minerals for healthy
living.
VII. Final ozonisation: final Ozonization is a process where in Ozone gas is passed through
water. It ensures water remains bacteria free for longer life.
2. Blowing
In the blowing department the performs, obtained from the preforms department are
blown to form bottles. There are a total of 2 fully automatic blowing machines which
are directly connected to the filler. The performs are blown at 95ºC temperature. In one
minute 65 bottles are blown.
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Pre-forms 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
Table no 2. Pre-form Size
3. Filling
The filling department is situated in a closed and a controlled environment to maintain the
hygiene. Bottles are fed by an air conveyor from the blowing unit directly into the in-feed of the
RFC. RFC equipment is neck run and it boasts of a mono block unit, which means that every
bottle is held by the neck automatically while being inverted, rinsed and sprayed with ozonated
water at 2 Bar pressure. After draining, the bottles are re-inverted and transferred to the filler. At
the filler these bottles are straightened up and gradually lifted to the filling valves which open
only when a bottle is placed under them. Filling is then done systematically through gravity. The
bottles are directly loaded onto the conveyor belt, first the bottles are 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. The water dispenser fills the bottle till the desired level of water is filledwhich is checked by a sensor.
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4. Capping
The bottles are passed to the capper from the filler through the conveyer belt. The caps are
produced in the cap department. 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 characteristic 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 the filling department. The bottles are passed to the capper from the filler
through the conveyer belt. Here ozonated-water rinsed caps are screwed on the bottle with
uniform torque. Since the water is ozonated all product contact parts are of 316L grade stainless
steel and the rubber parts are of EPDM.
5. Labeling
From the capping section the bottles are directly sent to the labeling section. All Bisleri bottles
are labeled on a hot melt reel feed BOPP labeling machine. This machine allows each individual
bottles to be spaced out and fed to the labeling station where precisely cut labels with a strip of
hot melt glue at the leading and trailing edge, get rolled around the bottle. These labels are fed
into the machine in a roll form too.
6. Coding
The labeled bottles are then passed to the coder. The sensor first senses the bottle and then 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. The code exactly contains Date, Time and Quality Checkers initials.
7. Packaging
Lastly they are packed in cartons and stored in the warehouse ready for transportation to its
destination.
All the waste bottles are separated 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.
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Outputs
The final output of whole manufacturing process is we get clean pure drinking water in Bisleri
bottles of different sizes according to the needs of the consumers.
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3. OBSERVATION / SUGGESSITION
Bisleri has adopted many automated techniques. Examples: Conveyor belt, Blowing
machines, Injection moulding machine, Automatic fillers, Assembly line.
Mass Production: Bisleri produce the product in large quantity. But the production for
every day is not same they produce according to the order of the suppliers or distributers.
Bisleri is an ISO: 14000 certified company.
The machines are placed in such a way that there is enough place for moving and
relocation of the machines.
Workers in the plant are required to wear head masks to avoid contamination of the
product.
The Canteen for the workers is conveniently located and provides hygienic food.
The Washrooms for men and women workers are also conveniently located are kept in
hygienic conditions.
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4. Opinion about Industrial Visit
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