Final Report

P e p s i C o I n d i a | 1

A project report on

Quality control and food safety

standards

PepsiCo India holdings Pvt. Ltd.

In Supervision of: Submitted by:

Mr. Anirudh Kund Anoop Tiwari

Process Co-ordinator B.Tech (BIOTECHNOLOGY)

(Quality Control) Enrolment No. – A7104108029


INDEX

1. Acknowledgement

2. Part ‘A’

Total quality management in beverage industry

3. Part ‘B’

Food safety standards in beverage industry


ACKNOWLEDGEMENT

With deep sense of regard, I take this opportunity of expressing my profound gratitude

and indebtance to Mr. Sandeep Bhargava (G.M.) and Mr. Sandeep Sharma, Manager

(H.R.), PEPSICO India Holdings Pvt. Ltd. Jainpur, Kanpur Dehat, for accepting my

request and for providing me this opportunity for training.

I am also thankful to Mr. Anirudh Kund, Process Co-odinator,NCB (Quality control) and

all staff members for providing me invaluable suggestion, guidance and encouragement.

Without their support and encouragement; it would not have been possible for me to

complete this task.

ANOOP TIWARI


CONTENTS

Part ‘A’

About Pepsico India

Total Quality Management in Beverage Industry

1. Introduction

2. Water treatment plant

3. Making of beverages

4. Microorganism that spoil beverages

5. Pre activities to prevent possible micro damage in beverage industry

6. Microbiological control and sampling program

7. Microbiological media

8. Effluent treatment plant

9. Conclusion


Review of Literature

PepsiCo India

PepsiCo entered India in 1989 and has grown to become the country’s largest selling

food and Beverage Company. One of the largest multinational investors in the country,

PepsiCo has established a business which aims to serve the long term dynamic needs of

consumers in India.

PepsiCo nourishes consumers with a range of products from treats to healthy eats that

deliver joy as well as nutrition and always, good taste. PepsiCo India’s expansive

portfolio includes iconic refreshment beverages Pepsi, 7 UP, Mirinda and Mountain

Dew, in addition to low calorie options such as Diet Pepsi, hydrating and nutritional

beverages such as Aquafina drinking water, isotonicsports drinks - Gatorade, Tropicana

100% fruit juices, and juice based drinks – Tropicana Nectars, Tropicana Twister and

Slice, non-carbonated beverage and a new innovation Nimbooz by 7Up. Local brands –

Lehar Evervess Soda, Dukes Lemonade and Mangola add to the diverse range of brands.


Beverages

PepsiCo India’s expansive portfolio includes iconic refreshment beverages Pepsi, 7 UP,

Nimbooz, Mirinda and Mountain Dew, in addition to low calorie options such as Diet

Pepsi, hydrating and nutritional beverages such as Aquafina drinking water, isotonic

sports drinks - Gatorade, Tropicana100% fruit juices, and juice based drinks – Tropicana

Nectars, Tropicana Twister and Slice. Local brands – Lehar Evervess Soda, Dukes

Lemonade and Mangola add to the diverse range of brands.

Foods

PepsiCo’s food division, Frito-Lay, is the leader in the branded salty snack market and

all Frito Lay products are free of trans-fat and MSG. It manufactures Lay’s Potato Chips,

Cheetos extruded snacks, Uncle Chipps and traditional snacks under the Kurkure and

Lehar brands. The company’s high fibre breakfast cereal, Quaker Oats, and low fat and

roasted snack options enhance the healthful choices available to consumers. Frito Lay’s

core products, Lay’s, Kurkure, Uncle Chipps and Cheetos are cooked in Rice Bran Oil


PEPSICO BRAND IN MARKET

PepsiCo India’s expansive portfolio includes iconic refreshment beverages Pepsi, 7UP,

Nimbooz, Mirinda, Slice and Mountain Dew; in addition to low calorie options such as

Diet Pepsi, hydrating and nutritional beverages such as Aquafina drinking water,

isotonic sports drinks - Gatorade, Tropicana 100%, Tropicana Twister fruit juices.

Pepsi – “Yeh Hai Youngistan Meri Jaan”

Brand History

Youngistaan loves it. 200

million people worldwide love it.

But what has made Pepsi the

single largest selling soft drink

brand in India is actually a

formula concocted a century

ago in a far away continent.

1886, United States of America. Caleb Bradman, the man with a plan, got on to

formulate a blockbuster digestive drink and decided to call it Brad’s drink. It was this

doctor’s potion that was to become Pepsi Cola in 1898, and eventually, Pepsi in

1903.

Pepsi has always played on the front foot and since its inception has come out

with revolutionary concepts like Diet, 2L bottles, recyclable plastic cola bottles and

the enviable My Can.

Brand Advantage

Pepsi has become a friend to the youth and has led many youth cultures.

Youngsters over the generations have grown up with Pepsi and share an emotional

connect with it, unlike any other cola brand.


7UP - Mood Ko Do Lemon Ka Lift

Brand History

7UP, the refreshing clear

drink with natural lemon and

lime flavour was created in

1929.

7UP was launched in

India in 1990 and its

international mascot Fido

Dido was used for advertising in 1992 to position the brand as a cool drink for

youngsters.

Fido became an instant hit with his trendy look, laid back attitude and refreshing

take on life.

During the brand’s early years in India, 7UP gained market leader status in the

lemon lime category by being one of the first to be nationally distributed as well as

being marketed as a healthier alternative to other soft drinks.

Brand Advantage

For the past 2 years, 7UP’s ambition as a brand has been to capture and own the

lemon refreshment territory within the clear lime category. Lemon has proven to be a

clear and relevant differentiator for the brand.

Further, it has allowed the brand to ladder up to an emotional payoff of uplifting

refreshment. After establishing itself as “The Lemon Drink ", in Jan 2009, 7UP

continued to build further on the theme of mood upliftment with its new tagline

"Mood ko do Lemon ka Lift”.

7UP’s brand communication is premised on the product’s natural lemon flavor ,

guaranteed to provide uplifting lemon refreshment that raises one’s spirits


Mountain Dew –Darr Ke Aage Jeet Hai

Brand History

The main formula of Mountain

Dew was invented in Virginia,

named and first marketed in Johnson

City, Tennessee and Knoxville,

Tennessee in 1948.

In India, Mountain Dew set the

soft drink category ablaze in 2003 with their iconic launch campaign “Cheetah

BhiPeetaHai”.

Brand Advantage

It is a soft drink that exhilarated like no other because of its daring, high-energy,

active, extreme citrus taste. Challenge, a can do attitude, adventure and exhilaration

is deeply entrenched in its brand DNA and the brand has always celebrated the bold

and adventurous spirit of the youth.

This exhilaration and excitement of Mountain Dew has always been reflected in

the high-adrenaline advertising of the brand that connected it to outdoor adventure.


Slice - Pure Mango Pleasure

Brand History

Slice was launched in India in 1993 as a refreshing mango drink and quickly went on

to become a leading player in the

category.

In 2008, Slice was relaunched

with a 'winning' product

formulation which made the

consumers fall in love with its

taste. With refreshed pack

graphics and clutter breaking

advertising, Slice has driven

strong appeal within the category.

Brand Advantage

With the launch of “Aamsutra” campaign in 2008 along with a winning taste &

most appealing pack graphics, Slice created disruptive excitement in the category

and celebrated mango indulgence like no other.

While other players have portrayed mango as a simple and innocent fruit, Slice

celebrates the indulgence and sensuality of consuming a Mango. The creative idea

“Aamsutra” communicates the art of experiencing pure mango pleasure through the

taste of Slice.


Mirinda – Weekend Aye To Pagalpanti Chaye

Brand History

Mirinda is an

international soft drink brand

from Spain that was

launched in India in 1991.

Mirinda has always been

about a great irresistible

orange taste, which is now

synonymous with the brand.

These were communicated

through our great of “Mirinda Men” in 1996 or with the campaign of “Taste pe Atka,

Mirindaaaa” in the year 2000 or “Taste AisaChaye Character FislaJaye” in 2003.

Mirinda then evolved to ladder up the great taste to great fun with another spate

of memorable campaigns of “Fun KaNaya Mantra, Mirindaaaaa” starring

Asin&Zayed Khan in 2007 & “Pagalpanti bhi Zaroori Hai” campaign with Asin in

2008.

Brand Advantage

Now when we think Mirinda, we think orange. But this soft drink brand has

launched many other fruit flavours from time to time; Mirinda Lemon was launched

in 1998 with memorable campaign “Zor Ka Jhatka Dheere se Lage”. Mirinda has

also launched many other flavors like Apple & Batberry, as innovative flavor

offerings for the evolving consumer.


Nimbooz – Ekdum Asli Indian

Brand History

Nimbooz was launched in India this year on the 28th of February 2009. Latest

addition to portfolio of Pepsi Beverages.

Brand Advantage

The brand delivers very strongly on certain expectations. These are

Locally Relevant Taste

Nimbooz is a great tasting product which has capitalized on the existing familiarity

& behavior of high frequency consumption of unpackaged / Home made nimbupani.

It has been true to its Asli Indian Identity by owning and appropriating nimbupani

Codes such as the Matka (Earthen Pot) and Squeezer.


INTRODUCTION

The term quality is refer to an ongoing analysis of operation to verify goods and services

meet specified standard, or to better answer customer and/or user complaints. In other

words we can say step taken to make sure that a company’s product or services are of

sufficiently high quality this is known as quality assurance. Rapid industrialization

increase wide range of competition to make better customer satisfaction. They are

spending a lot of money on quality assurance of their product. Today there are many

food products and beverages are produced by many industries and are directly consumed

by human. So consumer point of view these products should be safe for use. It means

there should not be any quality assurance is very important in beverage and food

industry.

Quality assurance includes all chemical and microbial testing in the industries. Sanitation

is an important part of the quality because it prevents the contamination in beverages

microbial contamination is reduced by the effective sanitation procedure. After finished

product analysis the raw material is also analyzed. Here in PEPSICO India Holding Pvt.

Ltd. The major effluent is waste water. The company recycles the water by its own

effective effluent treatment plant.

QUALITY COMMITMENT: A Commitment as Safe & Strong

People love to speculate about the secret ingredient in Pepsi. Some say it could be

ferreted out by simple analytical chemistry. Others are sure they taste a distinctive flavor

base. But most are simply delighted that it makes Pepsi.

What's the secret? Well, one secret is locked safely away in a secured vault. But another

is just an arm's length away. It's the consistent quality of Pepsi. Wherever they do

business, the Pepsi system adheres not only to local and national laws for food

processing and labeling, but also to its own strict standards for exceptional quality.


The Art of Concentrate & Syrup Manufacturing

Most of the flavors are produced as concentrates, which are rigorously analyzed to

ensure that they meet quality specifications. Each concentrate lot is coded and packaged,

then shipped on for the next step - the addition of sweetener and water to the

concentrates to produce syrups for their products.

The quality standards are very high. Mixing tanks are of a specified grade of stainless

steel. The entire syrup manufacturing system employs hot sanitation.

The syrups start with fresh water, treated by using a multiple barrier filtration process to

ensure its quality. In addition to the water and concentrate, sweeteners are added to

produce syrup for most products. Throughout the manufacturing process, special care is

taken to ensure that every step - from the selection of ingredients to the calibration of

equipment - adheres to its own strict requirements. The final step is to verify that the

efforts have been successful by testing the syrups for taste and adherence to their

formulae.

A Mixture of Quality Control Processes

The magic of turning syrup into a finished beverage is the role of bottlers and canners.

They bring together the essential ingredients - syrup, water and carbon dioxide - and

transform them into the essence of refreshment. To do this, many producers now use the

latest in computer technology and statistical process control. It's a modern way to

achieve our one traditional goal - consistentquality. .


Adding the Sparkle

Adding pure carbon dioxide to the blend, in just the right proportion, puts the "sparkle"

in soft drinks. To ensure we have it right, technicians periodically check production runs.

Packaging That Is As Neat & Clean

The actual beverage aside, even packaging undergoes, rigorous quality tests. All

packages must be free from defects. Cans are regularly "torn down" to check the quality

of liners and seams. Bottles, whether glass or plastic, must meet standards for finish and

uniformity.

Once the packaging has been inspected the filler injects the right quantity of the

beverage and seals it with a can end, metal crown or plastic closure. Each closure

application method must pass regular testing. Metal crowns for glass bottles must be

properly crimped onto the bottle lip. Plastic closures are tested for proper alignment,

threading and torque (how hard you have to twist to get the closure off the bottle). Can

ends are inspected for smooth, uniform application without gaps or leaks.

Checking fill heights or net contents of our products helps to ensure that each package

contains the proper volume. Can fill levels are continuously checked by an electronic

device, which rejects any cannot properly filled. Bottle fill heights are measured

gravimetrically, or by weight. Labeling and graphics for all packages must meet clearly

defined standards.

Every production lot is coded by date and producing facility. Trained route sales people

use this code extensively to provide the freshest, best-tasting product possible. It's the

primary tool for maintaining high quality standards throughout the distribution cycle,

right to the consumer

WATER TREATMENT PLANT


Many people & beverage industry depend throughout the world on underground sources

of drinking water and potable water. Water is major constituent of beverage or soft

drinks. In soft drink industry almost 99% water is used for making soft drinks and cola

and non cola beverage. Untreated ground water is mostly pure and cleaned than any

surface water. The PepsiCo India Holdings Pvt. Ltd. Jainpur has it own source of water

supply.

This plant is also using the ground water by using bore well. However, this water is now

a days polluted by different types of human activities like sewage disposal in unscientific

ways, refuse dumps from yard manures , pesticide and chemical fertilizer contamination,

disposal of hospital water, industrial effluents discharge etc. E. coli and other bacterial

contamination are being reported from ground water sample of different regions. Heavy

metals are also present in different ground water sample collected from industrial region

of India.

Therefore water treatment is necessary for the removal of impurities, micro organism

and heavy metals which cause disease and also alter the product quality of beverage

industries.

Coagulation:

Coagulation is six step process-


1. Mixing tank

2. Flocculation chamber

3. Settling zone

4. Sludge recirculation

5. Sludge discharge

6. Treated water collection

Procedure:

1. Coagulant, bleaching solution and lime mix together in the reaction tank and

cause almost all of the raw water alkalinity(usually present as bicarbonate) to be

converted to carbonate, which precipitates out of the solution and settle to the

bottom of the tank.

2. At the same time, a floc is formed that in traps calcium carbonate, suspended

solids, oxidized iron and manganese and many other contaminants.

3. This floc grow in size, become heavy and help to alkalinity and impurities to

settles more quickly to the bottom of the reactor (this forms the sludge).

4. If every thing is sized and operated correctly the treated water should easily reach

35 to 40 mg/l alkalinity and be free of odor, color, turbidity, metals and many

organics.

Reactions:

Ferric sulphate or ferrous sulphate +chlorine

Ferrous sulphate +Chlorine ferric sulphate.

Ferrous sulphate + lime ferric hydroxide

Important points:

1. The primary purpose for coagulant addition is to assist in the precipitation of

the insoluble alkaline salts, created by the lime based reaction.


2. The addition of the coagulant will also assist in the removal of turbidity

causing particle such as bacteria, algae and colloids.

3. Two commonly used coagulants are ferrous and ferric sulphate they provide

good coagulation over a wide range of water condition especially at light pH

typically encountered in lime treatment system.

4. Aluminium sulphate or alum can be used but it effectiveness is optimum in

the 5.5 to 8.0 pH range which is typically cited as too low for alkalinity

reduction this become an issue when sodium carbonate is used for pH control.

PEPSICO has appreciable plant operating data when alum is used effectively with

hydrated lime at pH value near 10.0. Both ferrous and ferric sulphate requires hydroxide

alkalinity in the form of lime to form the desired hydroxide floc particle.

Coagulation principle:

Coagulation is two step processes:

1. Charge neutralization: the ferric sulphate salt (coagulation) neutralizes the

surface charge of the suspended solids which are typically negative. This

eliminates the natural repulsive solid of suspended solid.

2. Destabilization: the ferric hydroxide will hydrolyze these neutralized

suspended solid to form insoluble precipitate which will entrap particle and

settle out as sludge.

Tests Performed On Treated Water

1. Chlorine Test

Procedure:

-10 ml water sample taken in the tube of Lovibond Comperator


-Add 1 DPD Tablet No.1

-Mix properly until a slight pink color observed

-Compare the pink color with the standard scale of the device.

-Note down the value, this value is the amount of chlorine present in water

Observation: Reading : 4 ppm

Result: The chlorine present in Treated water is 4 ppm

2. Total Hardness Test

Procedure:

-100ml sample taken in a conical flask

-Add 1 Total Hardness tablet

-Mix properly and add 2-3 drops of ammonium buffer

-Purple color observed

-Titrate it against 0.02N EDTA until the color changes to blue

-Note the reading of the end point and calculate the titre value.

Observation:

Sr

No.

Initial reading of

burette

Final reading of

burette

Titre

value

1 12.0 19.5 7.5

Calculation: Total Hardness = Titre value x 10

7.5 x 10 = 75 ppm

Result: The total hardness of the Treated water is 75 ppm.(standard<80ppm)

3. Calcium Hardness

Procedure:

- 100ml sample taken in a conical flask


- Add 1 Calcium Hardness tablet

- Mix properly and add 2-3 drops of 4N NaOH

- Pink color observed

- Titrate it against 0.02N EDTA until the color changes to purple

- Note the reading of the end point and calculate the titre value.

Observation:

Sr

No.

Initial reading

of burette

Final reading of

burette

Titre

value

1 0.0 3.1 3.1

Calculation:

Calcium Hardness = Titre value x 10

3.1 x 10 = 31 ppm

Result:

The calcium hardness of the Treated water is 31 ppm.

4. pH Test

A water supply's pH level indicates the water's acidity or basicity. PH is measured

on a standard 1 through 14 scale. Neutral water is given a pH value of 7.0. It

contains equal amounts of hydrogen ions (H+) and hydroxide ions (OH-). Dissolved

chemicals and minerals change the balance of those ions from a perfectly neutral

state. pH is measured by the device known as pH meter

Result: The pH of the Treated water sample is 6.5. Optimum range of pH for

treated water is 6.5 to 8.5


MAKING OF BEVERAGE

The first step in making of beverage is making of syrup. The making of syrip is

completed in two steps and these are:

SUGAR SYRUP PREPARATION


Standard

Globally there are no norms for Pesticide Residues in Sugar. Norms are available

for Raw Agricultural commodity (Sugarcane & Sugar Beet).

Pesticide Residues in sugarcane should comply with the requirements (Ranging

between 50 –250 ppb) as specified by RULE 65 of PFA 1955 and Codex

Alimentarius.

Status

The SUGAR used in the manufacturing of Beverage meets the Indian standards

(for Sugarcane, Rule 65 of PFA 1955) and Codex Alimentarius (as per

FAOSTAT) for pesticide residues

Sugar is sourced from only a very few selected sugar mills across the country

Sugar from each mill is analyzed for Pesticide residue Only sugar that passes

these tests is used in sugar syrup (simple syrup) manufacture

Sugar is purified further using Hot Carbon treatment process

Sugar Approval Process:

Sugar is purchased only from approved suppliers after sugar passes all the

Required Quality Tests

Sugar is sourced from only a very few selected sugar mills across the country

Each batch of sugar approved for use is screened for important parameters like

color, dextrans, heavy metals, ash, sediments, taste, odor, and appearance.

Sugar from each mill is analyzed for Pesticide residue

Only sugar that passes these tests is used in syrup manufacture

Hot Carbon Treatment is the best known method for removal of organic

contaminants including pesticide residues by process called adsorption.



Impurities HOT CARBON TREATMENT

Syrup Preparation by Hot Carbon Treatment

Sugar taken from the market. Each bag is weighed, 1Bag = 50kg.

Sugar is dumped in Sugar Dumping Hopper

Filters are present to remove impurities. Its capacity is 100kg in 1 min.

From where sugar is drawn into the Rotary by a suction force which is provided by

the Vacuum pump of a capacity 30 kl attached to it.

Vacuum pump is connected to a filter device which provides the pressure to the

rotary so that it takes up the sugar.


If any extra sugar is dumped then it is delivered back to the filtration device and

collected back along with all the impurities.

Nylon filters are present for filtration.

DUMPING TANKS:

The sugar taken by the rotary is delivered into the dumping tank.

The tank contain Treated Water at a temperature of 700C ( so that sugar

dissolves equally without he formation of any lumps) sugar is added into

it and the temperature is raised to 850C through steam. This high

temperature is maintained so that all the microorganisms are killed.

Hyflo Powder added at a concentration of 0.25% to remove all the

impurities in the sugar.

Carbon Powder added at a concentration of 0.35% to absorb all the

impurities. At 850C all carbon is activated and all its pores are open to

absorb impurities.

Contact time at 850C in the dumping tank is half an hour.

PRECOATING TANK:

An initial coating of Hyflo is done onto the filter papers. A layer of about

0.7– 1.0 mm of Hyflo is made so that filter paper does not break while

passing the sugar syrup.

About 100-150 l of water and 6.5 kg of Hyflo is taken in the tank

The precoating is done by circularization process for about 20 mins, the

Hyflo form a layer onto the filter paper and water retained back.

After 20 min a sample is taken from the Precoating Tank and checked in the

laboratory


- Filter the sample against 0.45µ filter paper which is black in

color and observe any white particle remaining or not.

- This is used to check that all the Hyflo is used or there is still

any Hyflo left in the tank.

FILTRATION:

Syrup prepared contains Carbon and is black in color which is needed to be

purified and removed.

Syrup is passed through 0.8 µ filter papers which is already

precoated by Hyflo

Filtration is done through circularization until clear white syrup is not

observed from the monitoring glass tube.

A sample of the purified syrup is taken for laboratory testing.

- Take 10 ml syrup sample and dilute it to 50 ml by soft water.

- Pass it through white cellulose nitrate filter paper of pore size

0.45µ.

Note: if any power failure occur in between filtration then carry the whole filtration

again. And if it occurs during precoating it is necessary to start the precoating again because

the layer does not settle properly on the filter paper and it will fall down at time of filtration.

PLATE HEAT EXCHANGER:

After the syrup is filtered properly it is passed through Plate Heat Exchanger

where its temperature falls from 850C to 20-240C.

The Treated water from cooling towers enters the PHE and it falls the

temperature of syrup to 60-500C.

Further Glycol is used to make the temperature of syrup fall down to 22-240C

The temperature is noted down then the syrup finally prepared is supplied to

READY SYRUP ROOM


READY SYRUP PREPARATION:

Syrup is supplied to the desired tank for the preparation of desired flavor.

A sample of syrup is taken for the laboratory testing.

- Brix & Apparent Density Test: sample is injected into the DENSITY

METER for the measurement of Brix and Apparent Density.

- Standard Brix of the sugar syrup is 60 (+3).

- Brix is percentage of sugar weight by weight.

When syrup reached at a particular level in the tank, Flavor is added

through Concentrate Trolley where proper mixing of flavor is done through

circularization. And then it is added into the tank and properly mixed by

circularization or agitation.

Syrup batching

Syrup batching is combination of concentrate components and simple syrup. Finished

syrup is sent to proportioning and mixing.

Control point in syrup preparation:

1. Brix for simple

2. Finished syrup:- final volume, brix, control drinks.

3. For increase in the brix added filtered sugar.

4. For decrease in the brix added treated water.

Staging


Staging is an efficient way to verify that all ingredients are on hand and suitable for use

Ensure correct amount of concentrate ingredients for the no. of unit o be

batched.

Inspect for leak and breakage.

Do not split concentrate package.

Read label and date code.

Document on the batch control record.

Ageing of Pepsi flavor profile.

Purpose of control drink to determine:

If the syrup mixture is correct.

If the finished product will meet the target.

If the test is acceptable.

Line beverage target for titrable acidity used for diet drinks.

Line beverage target for brix used for regular drinks.

Control drinks are drink prepared using controlled water and finished syrup. Accurate

batching and control drinks will result in good caffeine results from Pepsico

International Trade sampling program.

Effect of alkalinity and hardness on control drinks and titrable acidity:

1. Hardness effect TA

About 0.7 ml increase per 200 ppm.

If we use the hardness inhibited method for TA. No correction is

necessary.

2. Alkalinity effects TA


About 1 ml decrease per 50 ppm.

Must correct target alkalinity in order to match beverage document TA target.

3. If we use tripotassium citrate then no need to compensate for hardness effect.

Carbonation in beverage

It is a process of dissolving CO2 in water (beverage). The purpose of

carbonation is to provide sensory experience, protection from micro organism

and package integrity.

1 gas volume = the cubic volume of CO2 gas (at standard temperature and

pressure of 0 °C and 1 atms which dissolve in an equal amount of liquid).

1L CO2 gas + 1L of liquid

Gas volume are directly proportional to the ratio of temperature and pressure

MICROORGANISMS THAT SPOIL BEVERAGE

WHO asserts, “Infectious disease caused by pathogenic bacteria, viruses and

protozoa or by parasites are the most common and widespread health risk associated

with water”.

The most notable and widely accepted group of indicator organism is coli form

group, which refers to the gram negative rod shaped bacteria capable of growth in

the presence of bile salts or other surface active agents with similar growth

inhibiting properties and able to ferment lactose at 35-37 °C with the production of

acid, gas and aldehyde within 24-28 hrs. They are also oxidase negative and non

spore forming.

Water borne Microorganisms are transmitted as a result of direct contact with fecal

treatment. The fecal thermo-tolerant coliform with E.coli being the most prominent

member, fecal Streptococci and anaerobic spore forming bacteria, the target of

which is primarily Clostridium perfringens.


Another Microorganism that has recently become a threat to both the municipal and

industrial water treatment areas is the protozoan, Cryptosporidium Parvium

Cryptosporidium Parvium is a protozoan parasite affecting the gastrointestinal tract

of humans and animals. It is shed in the feces in the form of an “oocyst” which has a

hard shell to protect it from the environment. This also makes it highly resistant to

disinfection by chlorine and ozone; although UV disinfection has proven to be

extremely effective at its inactivation.

In addition to water borne microorganism, water supplies may also be subjected to

inhabitation by “nuisance microorganism”. These microorganisms, as their name

implies are typically not associated with any direct health effects.

There are many areas that may cause micro contamination in beverage:

Water- poor filtration and/or polishing can allow foreign matter in to manufacturing

process. This is the main cause of micro contamination in water.

Sugar- foreign matter in the sugar can be transferred to the beverage if not properly

filtered. If sugar is not properly stored and handled it may also cause micro

contamination.

Carbon-dioxide- foreign matter or contaminates in the CO2 supply can create

microbial contamination.

Concentrate- if the containers of the concentrate are not properly sealed, it may

cause contamination. Also when containers are not properly stored at low

temperature.

Conversion- if all entrance points to the manufacturing process are not protected and

controlled to prevent foreign matter. All packages are not properly rinsed prior to

filling. Poor application of crown/closure which leads to loss of CO2.

Storage and handling- because of poor storage and handling product that has lost

CO2 is more susceptible to microbial growth.


Unknown other- there are some other unknown reason, which may cause microbial

contamination.

PRE ACTIVITIES TO PREVENT POSSIBLE MICRO DAMAGE IN

BEVERAGE INDUSTRY:

SANITATION

Sanitation refers to treating a cleaned surface to destroy contaminant organism and

reduce the total vegetative cell population to a safe level.

Purpose of sanitation:

Sanitation problems have some negative effects on the beverage. The way to avoid the

sanitation problem is to keep the beverage plant, the production and processing

equipments and the beverage ingredients as sanitary as possible at all times. Poor

sanitation can lead to taste problems, appearance discrepancies or spoilage.


Sanitation process:

1. Sanitation of equipments- The most important sanitation program in the beverage

plant deals with the cleaning and sanitizing of those surfaces that come in contact with

syrup, beverage or ingredients used in their preparation. Proper sanitation performed at

the recommended frequency will minimize and most likely completely eliminate the

potential for bacteria, yeasts and mold reproduction and growth.

The most successful program has been identified as the “Five step” procedure and this

should be used for all syrup and filling room equipments.

a) Rinse- rinse all surface with adequate water until syrup and beverage residue are

removed where possible, warm water is preferred (50-60 °C /120-140 °F).

b) Clean – clean with hot detergent. 1-1.5 % caustic soda is used as cleaning agent.

Temperature of cleaning solution should be 60-65 °C.

c) Rinse- rinse with adequate water until the cleaning solution is removed.

d) Sanitize – sanitize with a strong chlorine solution with hot water as follows: if

chlorine, 100 ppm free chlorine for 20 min. if hot water is being used, then sanitize at 85

°C for 20 min.

e) Rinse – rinse with fully treated water. When chlorine solution has been used as the

sanitizing agent, rinse until all the traces of chlorine has been removed. When hot water

has been used, the equipment should be gradually cooled to avoid damage.

This sanitation process offers key advantages:

Automated step by step procedure can be used to assure that an entire sanitation is

followed with correct flows and holding times.

Process control will hold temperature at the correct point for hot sanitizing and will

ensure the correct holding time, with less chance of high or low heat zones.

Sanitation program in operation cannot cross contaminate normal production

.


1. Sanitation of bore well - One of the most important aspects of new bore well

construction is the proper sanitizing/disinfecting of the well. The components of

the bore well should be initially sanitized prior to the final setting. This is often

accomplished by light dusting of hypochlorite powder or soaking it in a

hypochlorite solution.

2. Sanitation of water - The coagulation tank or reaction tank is the first piece of

equipment in the water treating plant.

The FeSO4, lime and chlorine join the raw water as it flows in to the mixing zone of

tank.

The coagulant, usually FeSO4 with the assistance of the chlorine and lime, forms a

heavy floc, which entraps the particle of debris, dirt, organic matter and other

undesirable material in the water and settles slowly towards the bottom of the tank.

While the floc is forming, the lime is causing the alkaline components to precipitate

out of water. They are precipitated towards the bottom of the tank.

While the water in the tank flows towards the draw off pipe, because of its own

weight is left behind continually trapping particles of debris as it settles.

The treated water lows upward toward the treated water draw off pipe and out of the

tank. The chlorine in the coagulation tank, in addition to oxidizing organic and in

organic, reacts with micro organism so that sanitary water is assured.

The treated water than flows through a sand filter for straining (removal of floc

particles), a carbon filter to remove chlorine, then micron polisher and final UV

disinfector, which help in reducing the number of microorganism.

Sanitation process applies daily on a periodic basis. There are some key elements of

sanitizing the water treatment system:


Sand filters and carbon purifiers should be back washed on the daily basis. The

purpose of this backwash is to take debris and sediment out of the beds and also resettle

both the sand and the carbon.

3. Sanitation of bottles-

Bottles in feed: This the first chamber of the bottle washing machine. First the bottles

are send inside the chamber.

Residual draining- This is the next stage where any residue that might be present

inside the bottles is drained by inverting the bottles.

Pre rinse jet- Here bottles are washed by treated soft water.

Pre soak- In this region bottles are washed by treated water, which has 1.5% of

caustic for washing and sanitizing purpose. This region should not maintain the high

temperature and high caustic percentage. The temperature range is 50-55 °C.

Pre heat rinse- In this region bottles are rinsed with hot water for the removal of

caustic and also for minimizing the microbial contamination.

Hot caustic tank- After pre heat rinse the bottles come into this tank where the

temperature of the caustic solution is high and the percentage of caustic solution is

maintained higher than 2-2.5% in the presoak region. The temperature range is 72 to76

°C.

Hot caustic soak with high pressure jetting- In this region the bottles are washed

with high pressure jetting by which if any foreign matter is present inside the bottle, may

come out.

Warm caustic tank- In this tank the temperature is kept lower than the hot caustic

tank.

Warm caustic tank with high pressure jetting- In this region the bottles are again

jetted with pressure to remove any foreign matter inside the bottles.

Warm water jetting- In this region the bottles are washed with warm water to low

down the temperature of the bottles for avoiding the breakage.


Caustic carryover water jetting- In this region bottles are jetted for avoiding the

carryover of caustic solution.

Warm water jetting- This time the bottles are jetted with warm water.

Warm water soak- here bottles are with warm water soak that have some percentage

of caustic.

Cold water jetting- This time bottles are just washed with cold water to maintain the

temperature of the bottles.

4. Sanitation of filling, beverage processing and syrup room –

Equipment for syrup making processing and filling should be maintained in spotlessly

clean and sanitary condition (inside and outside).

A clean floor that is kept in dries condition and free of beverage /syrup residue and

glass.

Clean walls and ceiling, free of mold, strain and/or discoloration syrup condensate.

Fresh atmosphere based on frequent air changes and low humidity.

The processing area should present a pleasant working environment. The filling area, in

particular requires attention because of the level of activity and need to protect the final

product before the container is sealed.

Frequent cleaning of process and filling area and maintaining them as dry and fresh

as possible.

After everyday operation the five step sanitation program should be conducted on all

syrup room processing and filling equipments.

Where sensitive products are packaged or product without natural protection or

preservative such as sodium benzoate, the step of sanitation procedure should be

executed between product changeovers.

INSECT CONTROL


The best way of eliminating insects from the bottling plants is to keep the area clean,

free of debris and dry. Insect are more comfortable in wet, high humidity environment.

For flying insect, attraction lamps that kill by electrical shock are effective and safe.

SANITIZING AGENT

For the 5 step sanitation program used in the syrup room and for packaging equipments,

the two acceptable alternatives are chlorine and hot sanitizing both approaches has

advantages.

Chlorine: chlorine is the most frequently used sanitizing agent in beverage plants. One

weakness of chlorine is that it cannot penetrate in to crakes in gasket or hard to reach

area unless the equipment is flooded and the problem area are identified and corrected.

Aside from this, chlorine is an excellent sanitizing agent with good kill efficiency. It

should be used at a pH of approx. 6-8. Chlorine gas may offer economic advantages,

but requires special precautionary measures.

Hot sanitizing: it is an excellent sanitizing process with good killing efficiency. One

issue is that the temperature of the area or the surface being sanitized must be heat at

85°C for 15 min to assure kill. An advantage is that the heat tends to penetrate in to

gaskets, cracks and hard areas. After hot sanitizing, the temperature should be bought to

ambient slowly to avoid equipment damage.

Caustic (NaOH): hot caustic solution at 60 °C is a powerful cleaning agent and can be

an important sanitation tool when dealing with pulp products. The caustic will

essentially burn pulp products. The caustic will essentially burn pulp residues off

stainless steel surface. Even though hot caustic is an efficient cleaning and sanitizing

agent, a disadvantage is that it is extremely dangerous and hard to rinse. Caution should

be use to make sure that all the caustic is removed from the lines and the rinse water

used to remove it checks out negative to phenolphthalein.


CIP (Cleaning In Place)

CIP is specially designed for the clean-up of beverage production line and filling equipment, with

three cleaning sections of:

acid,

lye and

heated water,

In which temperature can be set up for acid, lye and heated water.

A new generation of touch screen operation, which is both open-and-shut and easy to

handle.

CIP plays role of rinsing syrup melting system, extracting and dispensing system for juice,

homogenizer, and air exhauster. UHT sterilization system is attached with the CIP.

It is fully automatically- controlled, automatic confirming of rinsing passage, it is controlled

by the man-machine interface control system, using PLC to fulfill switch of pneumatic

butterfly valves in order to accomplish independent rinsing. So it can meet the clients


requirement of production, synchronous with CIP units.

The entire rinsing technical index (rinsing time, density of acid and lye, rinsing

temperature, rinsing sequence) can be preset as some program number of rinsing on the

touch screen. When rinsing, it needs manual operation on the touch screen to designate

rinsing equipment, select program number of rinsing and start the system, then CIP will

perform the rinsing process of designated equipment automatically and in turns according

to the pre-set program.

5 STEP CIP:

STEP 1: Rinse with treated water for 10mins

STEP 2: Caustic of conc. 1.5% is passed for 15mins at 60–77oC

STEP 3: Rinse with treated water for 10mins

STEP 4: Hot water at >85 oC for 15mins is passed.

STEP 5: Rinse with treated water for 10mins.

3 STEP CIP:

STEP 1: Rinse with treated water for 10 mins

STEP 2: Hot water at > 85 oC for 15 mins


STEP 3: : Rinse with treated water for 5 mins

EFFLUENT TREATMENT PLANT

The effluent received in the effluent water treatment plant is segregated in two different

streams:

Stream 1: PET line effluents, KHS effluent, water treatment room effluent.

Stream 2: Syrup room effluent, Slice line effluent.

Stream 1 and 2 is subjected directly to an aerobic treatment.

The effluent is first collected in an aerobic digester. Here 70 to 80 % of load is

decreased. In aerobic digester, filtration chamber is fitted for the filtration of oil

and grease.

In filter water, we dose DAP, urea, lime and soda. The purposes of dosing DAP

and urea is to provide nutrients and nitrogen.

Then effluent comes in equalization tank, her sludge is digested in digester.

Now effluent sends in secondary clarifier. The operation is based on centrifugal

force.

Again took sludge in digester in form of inlet.

Then water comes in aeration tank. Here aeration is provided by continuous

agitation.


Now water comes in intermediate tank.

Now we collect water for dosing of ferrous, bleaching, lime, soda and poly-

electrolytes.

Then water subjected to clarifier.

Now the water comes in treated effluent tank and sends further treatment in

water treatment plant.

CONCLUSION

It is necessary to provide an environment in which the organism and waste are

maintained in intimate contact in the presence of oxygen. Greater efficiency of

treatment and use for a wide variety if beverage wastes can be excepted when the types

of microorganism responsible for treatment are known and their optimum

environmental condition have been established.

The microbiological analysis is also very important in beverage industry, it can cause

off flavor, bad color, high packaging pressure, slimy texture and many more problems.

This analysis shows the real sanitizing condition of the plant and the machine. By using

swab test, environment air test and finished product microbial analysis we can check the

microbes presence.

The beverage industry sanitation is concerned with aseptic particles in the preparation,

processing and packaging the beverage of a plant, the general cleanliness and sanitation

of plant and premises and the health of employees. Specific duties in connection with

the beverage; the provision of good water supply; prevention of the contamination of

the beverage at all the stages during processing of equipment, personal and vermin; and

supervision of packaging and warehousing of finished product, the supervision of

cleanliness and sanitation of plant and premises.


SCHEMATIC REPRESENTATION OF THE PROCESS OF BOTTLES:

DEPALLATIZER: Here the empty bottle cases are loaded on the conveyor.

UNCASER: The uncaser unloads the empty bottles from the cases.

PRE LIGHT INSPECTION: The bottles are inspected manually at the light station.

BOTTLE WASHER: The bottles are washed properly in caustic solutions.


E.B.I.: Electronic Bottle Inspection

FILLER: The beverage is filled into the bottles at the filler.

CODER: The MRP and the manufacturing date along with the batch no is coded.

FINAL INSPECTION: The bottles after the filler are finally inspected and then these

bottles are put into the cases with the help of automatic CASER.

The empty cases are taken too another conveyor where they are washed and again packed

with the filled bottles at the caser.

PET BOTTLE PARAMETERS:

1) Gate Area Thickness:

Specification:

500 ml, 600ml : Min 1.3mm (Free of deep groove.)

1.0 l, 1.25 l, 1.5 l : Min 1.55mm (Free of deep groove.)

2.0 l, 2.25 l : Min 2.2mm Max 3.4mm (Free of deep groove.)

Test Method: Gate Area Thickness of PET bottles are measured by THICKNESS

TESTER or VERNIER CALIPERS.

2) Height of the Bottle:

Specification:

600ml : Min 242.50mm Max 245.50mm

1.25 l : Min 349 +/- 1.5 mm

2.0 l : Min 350 +/- 1.5 mm

Test Method:

Height of the PET Bottle is measured by HEIGHT GAUGE


3) Drop Test:

Specification:

Bottle should stand upright. No leakage is acceptable

Test Method:

Fill the bottle with carbonate product and water at 4.0 GV and drop it from a height

of 2.0 m in average. Observe any breakage in the bottle if so check the parameters

of the bottle and change the setting of the MagPlastic.

4) Stress Cracking :

Specification:

Min 20min. Corrective action between 20 to 30 min

Test Method:

Put the filled PET bottle into 0.2% NaOH solution for 15 min and check if there is

any crack or not. If bottle cracks then complain to MagPlastic Operator.

Temperature of the oven and flow of the air is adjusted.

5) Thickness:

Specification:

BASE: : Min 0.20mm. Standard: 0.31mm

LABEL: Min 0.25mm. Standard : 0.31mm

TOP & SHOULDER: Min 0.25mm. Standard : 0.35mm

6) Weight Distribution:

Specification:

600ml: Preform : 27gms


Base Panel : 4.5 – 5.5 gms

Label Panel : 11.0 – 12.0 gms

Upper Shoulder : 10.0 – 11.0 gms

1.25 L: Preform : 44gms

Base Panel : 12.0 – 13.5 gms

Label Panel : 10.5 – 20.0 gms

Test Method: Cut the bottle at their specific Cutting Point by HOT WIRE CUTTER &

weigh each part one by one on the WEIGHING MACHINE.

7) Top Load Test:

Specification: Standard: 15 – 25 kg per bottle

Test Method:

Break point of the bottle is the point when force is applied into bottle the bottle

moves, crack, etc. To note the break point a device known as TOP LOAD TESTER

is used.

8) Torque Test:

Specification: Standard: Min 8 to Max 16

Test Method:

Bottle with closure is kept on the TORQUE TESTER and set the reading to zero.

Then slightly rotate the cap anticlockwise and the back to original, note down the

reading. This gives the Open Torque and Close Torque of the closure. The torque

must be accurate if it is less than standard there is chances of leakage of the

gas.And if more difficulty in opening the bottle and also chances of bursting.


CONTENTS

Part ‘B’

Food Safety Standards in Beverage Industry

A. Introduction

B. Discrepancy Matrix Rating System

1. Organization and documentation

2. Personnel

3. Inspection

4. Foreign object management

5. Microbiological control and allergens

6. Pest control

7. Sanitation

8. Maintenance control


9. Facility design

10. Environment and waste management

11. Audit of WTP

C. Conclusion

INTRODUCTION

The AIB consolidated standards for beverages plants were published as a tool to permit

beverage (alcoholic, non alcoholic, carbonated, noncarbonated and juices) processors to

evaluate the food safety risks within their operation and to determine the levels of

compliance with the criteria in the standards. The standard contains the criteria and the

rating method used to assassin a numbering numerical score (rating) to the plant. These

criteria are derived from the following good management principles.

The U.S. Federal Food Drug and Cosmetic Act (1938); Good Manufacturing Practices,

CFR Title 21, Part no. (1986); U.S. Military sanitary standards: The U.S. Federal

Insecticides, Fungicide and Rodenticide Act; EU regulation no. 178/2002 and EU

Regulation no.852/2004; the food safety Act 1990 (Amendment) Regulation 2004

(U.K.); General Food Regulation 2004(U.K.) and Codex Alimentations Commission

Food Hygiene- basic text 1999.


DISCREPANCY MATRIX RATING SYSTEM

The PepsiCo/AIB International Global Beverage food safety standards (International)

are a compilation of beverage industry standards and specific requirements of PepsiCo

and PepsiCo International. The audit manual is divided in to two parts:

The written requirements based on the AIB consolidated standards for beverage

plant.

PepsiCo minimum mandates and the matrix itself, which defines the point

deduction for each item not meeting the requirements.

Key points to the Audit

The AIB audit is approx. 75 % floor audit and 25% record review. The audit will be a

very comprehensive examination of your equipment, processes, buildings, grounds and

so on.

The Plant Audit

The plant audit is not intended to disrupt your production and the auditor will work to

avoid disruption. You should discuss with the auditor if disruptions are occurring so a

different audit route can be followed. The auditor will identify the deficiency or non-

conformance and as an educator, will offer you suggestion for improvement . you Are

not obligated to follow these suggestion. If you disagree with auditors interpretation of

the AIB standard or the PepsiCo requirements, you should discuss with the auditor and

make every effort to agree on the severity of an item. The auditor will provide an audit

summary at the conclusion of each audit day. Understand that the auditor will have a


rating under the conclusion of the survey so do not except to discuss the ratings at these

summary ratings.

AUDIT RATING

The AIB rating

The AIB consolidated standards for beverage plant has been designed in systematic

manner that allows for effective auditing, and also serve as reference guide when issues

are identified. The standards are divided in to five categories,including a review of the

written food safety programs (adequacy of the food safety program), and proceed to a

closure examination of individual pest control programs, operational method, and

maintenance for food safety and cleaning practices.

Each category has a value of 200 points. Category scores are assigned as follows:

(180-200) minor improvements are needed, but there exists no evident risk or potential

hazard to food safety.

(160-175) some improvements needed to correct potential food safety hazard or

regulatory non compliance that have been noted.

(140-155) serious findings, an important food safety risk or risk of program failure has

been noted.

(<135) unsatisfactory findings, an imminent hazard, program failure, Product

contamination or extreme departure from regulatory standards has been noted.

The Matrix rating


Also beginning with 1000 points, the matrix is divided in to 11 areas including:

1. Organization and Documentation

2. Personnel

3. Inspection

4. Foreign Object Management

5. Microbiological Control and Allergens

6. Pest Control

7. Sanitation

8. Maintenance Control

9. Facility Design

10. Environmental and Waste Management

11. Minimum Mandates

Each deficiency noted during the audit is assigned a point deduction based on where it is

found in the matrix. The left column of the matrix is unsatisfactory, the center column is

major and the right column is serious. The left most column of the matrix provides a

reference number to the standard, should you require additional points.

The “minimum mandates”, are requirement of PI and a failure with one result in an

unsatisfactory audit report.

Total score of 700 points bare needed to pass the audit so a point value of 305 is use for

assigning satisfactory items (resulting in a rating of 695). For items that fall in the center

column, a point value of 40 points is assigned and for items in the right column 202

points deduction will occur.

ORGANIZATION AND DOCUMENTATAION:

Responsibility and authority for assuring compliance with federal, state,

governmental or any other appropriate regulatory law or guideline shall be clearly


assigned to a component supervisory level persons or persons and a functional

organizational chart shall be maintained.

All facilities shall establish an appropriate budget and support to maintain the

properly and timely acquisition of food safety related to tools, materials,

equipment, monitoring devices, chemicals and pesticides.

Prior to beginning work, temporary personnel and contractors shall be trained as

appropriate, and shall be adequately supervised throughout the working period.

Each food manufacture shall establish a procedure for handling governmental or

regulatory inspectors and third party auditors. This procedure should include:

a. Person or persons delegated to accompany all inspectors.

b. Company policy regarding photographs.

c. Company policy regarding records and samples.

A Written policy and procedure on temporary repairs shall be defined at each plant.

Finished product shall have permanent and legible code time marks readily seen by

the consumer.

PERSONNEL:

Suitable and sufficient hand washing facilities shall be provided at the entrance

and at the appropriate points within production areas. These facilities shall be

provided with an adequate water supply maintained at warm water temperature

and supplied with single use towels or air dryers. Hand washing stations shall be


provided where appropriate. Sanitizers for such stations shall be regularly

monitored for proper concentration to ensure effectiveness. Containers for

disposable paper towels should be kept covered.

Personnel practices:

Responsibility for assuring compliance by all personnel to plant policy shall be

clearly assigned to competent supervisory personnel.

Employees, contractor and visitors shall practice good personnel hygiene habits

at all time.

Hand washing shall perform at a frequency that is appropriate and should be

done at any time the hands become soiled. Hands should be washed before

beginning work, after using toilet facilities, eating, drinking, smoking or

otherwise soiling hands. Plants should be encouraged to monitor the

effectiveness of hygiene procedures with regard to hand.

INSPECTION:

Every plant shall conduct monthly audits of the whole facility and grounds and

roof, ensuring that complete audit of the entire facility are conducted not less

than ones per month.

A multidisciplinary audit team shall be utilized for this audit. Assignments are

located according to areas of responsibility. Record of each audit is an integral

part if this requirements and documentation of specific assignments and actual

accomplishment shall be maintained. Follow up review should be done to ensure

that items are corrected and results kept on file for review.


SANITATION:

A master sanitation schedule (MSS) shall be established and operated by every

site as a formalized written plan. The document and system identifies what is

cleaned on the site, when it is cleaned and records the satisfactory completion of

the cleaning. It is both a plan of what needs to be done and an easy reference guide

as to the progress of completion. This scheduled should be through and include the

outside ground, all buildings, all services such as drains and ventilation as well as all

plant interior fixtures, fittings and utensils all production related equipment. The

cleaning tasks should be divided into general areas:

1. Outsides area and ground

2. Outside buildings

3. Interior of main facility – room by room

4. The main production area-surfaces, services, equipment and associated

systems.

5. All product zones, food contact surfaces of equipment, utensils,

intermediate containers, pans, and trays band other main product zones.

6. All non product related materials, such as parts and equipments.

Detailed equipment sanitation standards operating procedure (SOPs) shall be

developed for personnel training maintaining the hygiene level of equipment

sanitation. These written SOPs shall be developed for all items on the MSS and

utilized for cleaning of all equipment used for storage, processing and packaging,

all building areas and for the outside grounds.

MAINTENANCE CONTROLS:

1. Thermally processed beverages shall be subjected to time/temperature parameters

that have been established using scientific criteria, and effectiveness shall be


verified by conducting commercial sterility testing as art of qualification

protocol. Records shall be maintained.

2. Holding tubes shall be properly sized for adequate microbial kill.

3. To maintain sterility of the sterility of the systems, proper differential pressure

shall be maintained. A higher pressure on the media side on the heat exchanger

shall also be maintained.

4. The containers and closures for all thermally processed beverages shall be

adequately sterilized. A higher pressure on the media side on the heat exchanger

shall also be maintained.

5. The containers and closures for all thermally processed beverages shall be

adequately sterilized. Hot-filled packages are properly inverted to ensure

adequate sterilization of the closure.

FACILITY DESIGN:

1. All structural beams, supports and other structural systems that are painted shall

be maintained in an appropriate manner to preclude or eliminate chipping,

flaking or peeling paint.

2. Sufficient space shall be provided for proper placement of equipment and storage

of equipment and storage of materials. Adequate aisles or a workspace shall be

maintained between equipment and structures to allow adequate cleaning.

3. Bulk systems and unloading areas shall be installed and maintained to prevent the

adulteration of raw materials or finished product. Outside receiving lines shall be

identified and locked at all times.

4. Floors, walls and ceilings shall be of such construction to be adequately

cleanable and kept in good repair. The following are further guidelines to assist

in this:


a. Walls shall be designed, constructed, finished and maintained to prevent the

accumulation of dirt, reduce condensation and mold growth, and facilitate

cleaning.

b. Floor-wall junctures and corners should be coved to facilitate cleaning. Cavities

in the surface of walls and floors should be avoided to prevent debris from

lodging and to avoid pest harborage.

c. Floors shall be designed to meet the demands of the process and withstand

cleaning materials and methods. They should be impervious and maintained in

good repairs.

5. Adequate floor drains with grates shall be installed, maintained and operational

in all wet processing and wash areas. All floor drain grates shall be easily

removable for cleaning and audit. The drains should be easily accessible for

cleaning.

6. Consideration should be given to the location of machinery and drains so that any

discharge and overspill from processing goes directly into a drain rather than on

the floor.

ENVIRONMENTAL AND WASTE MANAGEMENT:

Outside wet or dry waste or scrap compactors, modules and dumpsters shall be

installed to minimize leakage, permitting the container to be easily removed and

the area cleaned. External waste collection containers compacters should be kept

closed or covered.

Rubbish or inedible waste shall be covered in properly covered, labeled,

designated containers and emptied daily. When rubbish or inedible waste is

transported, it shall not come in contact with raw materials, work in progress

finished product. Waste disposal shall meet legislative requirements. When

required by region, waste shall be removed by licensed contractors.

Processing and packaging waste containers shall be kept clean and well

maintained.


Dock wells and leveler pits shall be kept free of standing waters, debris and other

pest attractants.

AUDIT OF WATER TREATMENT PLANTS:

With above guidelines I have instructed to audit the water treatment plant of the

PepsiCo plant. The main focus points are as follows:

Dust and dirt

Cobwebs

Drains

Temporary repair- using of tape, carton, wire or make shift arrangement

Loose items- bolt, gasket, box or any other loose item not belongs to that place.

As auditor can deduct points for each 15 loose items

Labeling of containers- each container (to store chemicals, lubricants and other

chemicals) should be properly labeled.

Place of GHK materials- place to be defined and this should not stored in product

zone.

Use of pet bottles- using of product bottles to store any thing can result in

negative numbers.

Strainers- strainers of syrup room and in product lines are critical and auditor will

ask to open them.

Focus area- your focus should be maximum in product zone. Auditor may visit

wellhead, AHU, ETP, shipping yard apart from process and storage of raw and

packaging material storage.

Post control-very critical as this covers almost 25-35% of the audit.

Evidence for-eating, drinking and tobacco spitting.

Leakages- if line is running then this to be taken care of.

Live insect activity- critical in process area.

Rust/Flaking paints- in product zone.


CONCLUSION

The supervision of cleanliness and sanitation of plant and premises includes not only the

maintainers of clean and well sanitized surface of all equipment touching the beverage

but also generally good housekeeping in and about the plant, adequate treatment and

disposal of water. Duties affecting the health of the employees include provisional of a

portable water supply, supervision of matters of personal hygiene, regulation of sanitary

aspects of plant lighting, heating and ventilation.

They started chief purposes of microbiological criteria for beverage are to give

assurance that the beverage will be acceptable from the public health stand point, e.g.

will not be responsible for the spread of infectious disease for food poisoning. The

beverage will be of satisfactory quality, i.e. it will consist of good original materials that

have not deteriorated or become unduly contaminated during processing, packaging,

storage, handling or marketing.

The beverage will be acceptable from aesthetic point of view. The beverage will have

keeping qualities that should be accepted of the product.

Final Report

Documents

isotonic sports drinks

low calorie options

lemon ka lift

gate area thickness

aib consolidated standards

aquafina drinking water

food safety standards

water treatment plant