Aarti IV Bisleri Project

8/4/2019 Aarti IV Bisleri Project

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Project Report on Industrial Visit

For

Bisleri



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

http://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.

http://en.wikipedia.org/wiki/Polyethylene

http://en.wikipedia.org/wiki/Thermoplastic

http://en.wikipedia.org/wiki/Petroleum

http://en.wikipedia.org/wiki/Kilogram

http://en.wikipedia.org/wiki/Energy

http://en.wikipedia.org/wiki/Resin_identification_code

http://en.wikipedia.org/wiki/Chemical_elements

http://en.wikipedia.org/wiki/Carbon

http://en.wikipedia.org/wiki/Hydrogen

http://en.wikipedia.org/wiki/Low-density_polyethylene


http://en.wikipedia.org/wiki/Polymer


http://en.wikipedia.org/wiki/Copolymerization

http://en.wikipedia.org/wiki/Ethylene

http://en.wikipedia.org/wiki/Olefin

http://en.wikipedia.org/wiki/Ultraviolet



http://en.wikipedia.org/wiki/Polyester

http://en.wikipedia.org/wiki/Synthetic_fiber

http://en.wikipedia.org/wiki/Packaging

http://en.wikipedia.org/wiki/Packaging

http://en.wikipedia.org/wiki/Synthetic_fiber

http://en.wikipedia.org/wiki/Polyester



http://en.wikipedia.org/wiki/Ultraviolet

http://en.wikipedia.org/wiki/Olefin

http://en.wikipedia.org/wiki/Ethylene

http://en.wikipedia.org/wiki/Copolymerization





http://en.wikipedia.org/wiki/Hydrogen

http://en.wikipedia.org/wiki/Carbon

http://en.wikipedia.org/wiki/Chemical_elements

http://en.wikipedia.org/wiki/Resin_identification_code

http://en.wikipedia.org/wiki/Energy

http://en.wikipedia.org/wiki/Kilogram

http://en.wikipedia.org/wiki/Petroleum






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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

http://en.wikipedia.org/w/index.php?title=Membrane_filtration&action=edit&redlink=1

http://en.wikipedia.org/wiki/Solution

http://en.wikipedia.org/wiki/Semi-permeable_membrane

http://en.wikipedia.org/wiki/Semi-permeable_membrane

http://en.wikipedia.org/wiki/Solution

http://en.wikipedia.org/w/index.php?title=Membrane_filtration&action=edit&redlink=1




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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.

http://en.wikipedia.org/wiki/Solute

http://en.wikipedia.org/wiki/Solvent

http://en.wikipedia.org/wiki/Osmosis



http://en.wikipedia.org/wiki/Osmosis


http://en.wikipedia.org/wiki/Solute




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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

Aarti IV Bisleri Project

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