Joel Report 2012-2013

Attachment Report

Attachment Report2012-2013

Attachment Report2012-2013

WORK RELATED LEARNING AT ByJOEL TENDEKAI TINASHE TARUZA (R091299C) Submitted in partial fulfilment of the requirements of the degree of Bachelor of Science Honours in Biological Sciences Department of Biological Science In the Faculty of Science and Technology at the Midlands State University Industrial Supervisor: Mr F Magadzire Academic Supervisor: Mr J Bare AUG 2012-JULY2013

Table of ContentsForewordiiiAims of Work Related Learning...iiiAcknowledgement.ivChapter 1: IntroductionCompany historical development...............1Mission statement and vision.3Organizational structure ...........3Products.6Service markets..........................................8Company social responsibility..............................10Chapter 2: Main body Overview of the departments at Schweppes.....................13Placement Department: QEOSH........14 Production Processes at Schweppes .41Hot fill Line............54Chapter 3: Conclusions and RecommendationsKey skills developed, strengths and weaknesses... 55Conclusion...57Recommendations57References...60

FOREWORDMy industrial attachment at Harare Schweppes Zimbabwe Limited (SZL) was an important period within my academic cycle. The main objective underlying attachment (work related learning experience) was applying theory learnt into practice and that enhances understanding processes at industrial level. The report mainly focuses on the production processes and quality control/assurance techniques and systems which are applied at SZL. It highlights activities, services and markets served by the organization as well as the companys organizational structure. Recommendations were suggested to improve on weaknesses observed and recognized in the Production and Quality Assurance Department.

WORK RELATED AIMS To put into practice the theories and experimental skills learnt To get experience of industrial environment and to know more about organizational structure(s) To gain more knowledge about Quality Assurance /Control systems and techniques Attachment Report2012-2013

To know more about International Standardization like the ISO series and their requirements.Joel T.T TaruzaPage iii

ACKNOWLEDGEMENTSAttachment Report2012-2013

I would like to pass my regards to the following personnel who made my stay at Schweppes Zimbabwe Limited fruitful, Mrs J Bwerinofa (Quality Assurance Manager), Mr F Magadzire (Plant Chemist), Mr D Manjere (Plant microbiologist), Mr L Mugambiwa (Lab Chemist), and the following Quality Assurance Technicians, Miss C Jiri, Mrs F Chigumira, Mr I Hodzi, Mr O Mutyandai, Mrs R Mhungu, Mr D Chitumba, Mr M Matawo, Mr R Mataranyika, Mrs M Shoko and Mrs P Kwangwari. I would also like to express my sincere gratitude to Midlands State University for providing such an excellent facility that links students with the industry during their degree programs. A profound gratitude goes to SZL for allowing me this opportunity to be attached with them for one year. During this period I was able to match the academic scientific theory to the real science and industry. I am grateful to all the staff at SZL, their co-operation, professional expertise and encouragement during my stay.Joel T T Taruza iv

CHAPTER 1

INTRODUCTION AND INDUCTIONThe student arrived at Schweppes Zimbabwe Limited (SZL) on the 2nd of October 2012. The first port of call was the Head Office, where the student was introduced to all the sections by the Human Resources (HR) Officer. From this point onwards the student was introduced to all other departments at the company by the HR Officer. The induction process included the following areas; a rundown of the general conduct accepted at SZL, and an overview of the functionality of all departments at SZL. The general conduct accepted at SZL included the wearing of Personal Protective Equipment(PPE), wearing closed shoes before entering the plant, wearing clean protective clothing, washing of hands all the time before and after entering the plant, wearing head covers when entering the plant and keeping work areas clean. As the student moved from one department to the other, each department gave an overview on how it provides services to the running of the company. The induction process ended with the student being handed over to the Quality Assurance Department after one week for training.

Company Background

The History of Schweppes Zimbabwe Limited (SZL) dates back to 1930 when Arthur Sturges arrived in Zimbabwe and set up a bottling company known as Spa Bottlers in Bulawayo. In 1931, the Company launched Mazoe Orange crush nationwide. The success of the small bottling company in Bulawayo led to the opening up of factories in Harare (Barrow Road), Ndola and Lusaka in Zambia.In 1955 Schweppes P.L.C acquired a controlling interest in Spa Bottlers and the name of the Company changed to Schweppes (Central Africa ) Limited. In 1958, Schweppes (Central Africa) Limited secured a franchise for the manufacturing of Pepsi Cola and Canada Dry. As the Company expanded and diversified its products, the Harare branch moved from Barrow Road to its present premises in Willowvale in 1976 and eventually sold its Barrow Road premises in 1985.In December 1998, Cadbury Schweppes PLC announced the sale of its brands to The Coca-Cola Company. The Company was bought by the Coca Cola Company on the 27th of November 2001 and became a wholly owned subsidiary of The Coca Cola Company. In recent developments, Coca Cola Company honoured its promise to indigenize the business hence 49% of Schweppes shares were sold to Delta Beverages and the remaining 51% were split as follows, 31% is now owned by Schweppes employees and 21% by a company called Waterton Investments which is constituted by the current Schweppes directors. The brands however remain in the ownership of Coca Cola. NORTHERN TERRITORY

2 Plants:Harare Bulawayo

Ds

SOUTHERN TERRITORY

Figure 1: Showing the main two plants and the Customer Collection Depots they serve.There are two plants in Zimbabwe, one in Harare which is the Head Office and one in Bulawayo. It also has four Customer Collection Depots (CCDs) in Masvingo, Mutare, Kwekwe and Chinhoyi.

Mission StatementWe commit ourselves to innovatively produce and supply high quality beverages that nourish and refresh consumers whilst creating stakeholder value.

Company VisionTo be a world class supplier of healthy, refreshing and nutritious beverages.

Organizational StructureThe management at SZL is governed by the managing director who reports directly to the board of directors. He is responsible to shape the companys vision and strategy and has 4 General Managers who report directly to him as well as three other executives as shown by the organ gram below:Key: IT Information TechnologyHR Human ResourcesQA- Quality Assurance KD- Key Distributor

Figure 1.1 Schweppes Organ gram DESCRIPTION OF THE ORGANOGRAM Board of Directors

The board of directors ensures the company's prosperity by collectively directing the company's affairs, whilst meeting the appropriate interests of its shareholders and stakeholders. In addition to business and financial issues, boards of directors deals with challenges and issues relating to corporate governance, corporate social responsibility and corporate ethics Managing Director

The Managing Director of Schweppes Zimbabwe Limited, Mr Msipa leads and develops the corporate culture for the organisation. As the title suggests, the Managing director manages the daily business of the company. This includes the staff, the customers, the budget, the company's assets and all other company resources to make the best use of them and increase the company's profitability. General Managers

A general manager is a senior manager and also an executive in the managerial committee, whose main responsibility is to oversee all the operations and practices of the organization as a whole. The General Managers of Schweppes Zimbabwe Limited are Mr Mbauya (GM Sales and Distribution), Mr Madamombe (GM Supply Chain), Mr Chitagu (GM HR) and Mr Dahwa (GM Finance) are primarily responsible for guiding employees in achieving the goals and ambitions of the organization. They ensure that all processes and practices are working in a proper manner. They discuss with other members of the top management and devise any specific goals, which are to be accomplished within a certain time period. As they oversee all processes, they have to pay minute attention to monthly or quarterly functioning of each individual practices. They need to hire well-experienced and efficient managers for handling the operations of individual practices in a company. Quality Assurance Executive

The quality assurance managers role is to oversee all the issues pertaining to quality from the quality policies, safety and health systems, and ensuring that these are implemented and maintained. The Executive is at the top of the Quality department managing water treatment quality systems, safety, health, and environment, microbiological and analytical laboratories.

PRODUCTS AT SCHWEPPESSchweppes Zimbabwe Limited products can be subdivided into five main categories and brands which are:-TABLE1.1: Product profileProductProperties

Cordials CRUSHES Mazoe Orange Crush 2Lt Mazoe Orange Crush 1Lt Mazoe Light 1Lt

SYRUPS

Cream Soda, Raspberry, BlackberryNartjie, Peach Juice contains sweetener and additives Contains 50% fruit juice Dilution ratio 1 part juice: 4 parts water Packaged in 1lt & 2lt bottles Certified by Standards Association of Zimbabwe

Flavoured juice containing nutritive sweetener and additives Packaged in 2lt bottles Shelf life-9 months Certified by SAZ

Ready to DrinkRIPE N READYLemon & Orange Flavoured drink containing nutritive sweetener and additives Ready to drink cold or ambient Packaged in 5ooml bottles Shelf life -9 months Certified by SAZ

Water500ml&1.5lt Purified bottled still water enhanced with mineral salts Manufactured using state of the arts reverse osmosis technology Certified by SAZ

Fruit Juices100%

Breakfast blend, apple, orange, and mango orangeNectars

berry, mango, apple, pineapple, exotic and orangePETS(400ML)Pulpy orange, orange, tropical, apple grape and mango apple

CANS(330ML)

breakfast blend, and apple 100%, 20-40% and 10% fruit juice 1 Lt Tetra prism in pack 330ml pack 400ml pack Screw on closure with tamper proof seal Shelf life- 9 months& 6months for PETs

Service MarketsThe main markets that are served by Schweppes Zimbabwe are wholesalers and among them are Bhadella, N Richards, and Mohammed Mussa. Retailers are also part of the market that it serves and these include O.K stores, TM, Spar outlets and Afro foods. Hotels, Restaurants and Caf are part of the clients that Schweppes serves and all the petrol food marts that are around Zimbabwe. Wholesalers buy in large quantities and break bulk by selling to small retail outlets, since they buy in bulk, they are given trade discounts for retention.Wholesalers are also given trading terms which they operate within for example they can be given products on credit but are to settle payment within fourteen days. This market is affected by seasonal changes that is in winter they buy less products and in summer they buy more.Retailers sell directly to the final consumers they also buy in bulk and are given trade discounts for retention. They negotiate for prices at head office level and have a group buyer for Schweppes products. This market is also affected by seasonal changes and their demand is higher in summer and low in winter.Hotels, Restaurants and Caf sell at premium prices hence Schweppes sells products to them at retail prices, This market therefore is key to Schweppes Zimbabwe Ltd in meeting its main goals. A recent survey showed that of every Zimbabwean who buys cordial drink, 58% buy Mazoe Orange Crush. Citra lain, a soft drink manufacturer only follows at 6%; the rest of cordial manufacturers share the remaining 36%.Some of our own syrups fall into the 36% portion. The figure below shows Schweppes market share. Strengths and WeaknessThe table below shows the strengths and weakness for Schweppes operations.

Table 1.2 STRENTHS AND WEAKNESS FOR SCHWEPPES STRENGTHWEAKNESS

Strong brand identity-Mazoe Wide product range that meets international standards with a satisfactory market reception as evidenced by the approval and certification by HACCP, SAZ and ISO9001 Ability to hire and retain competent employees Establishment of good relationships with customers, suppliers and employees SZL offers credits to customers most of which accommodate customer requirements High-tech machines that makes production process faster Failure to penetrate into foreign markets due to high production costs Failure to take advantage of HORECA channel by failing to produce certain product lines such as lime juice, lemon barley and inconsistent supply of Mazoe also frustrates customers

SZL is in a better position to control the market through aggressive pricing strategies and a well spelt out promotional The company has the ability to re-enter a shelved export market and open new ones as well Cape Fruit margins under pressure due to rand appreciation

Lyons launch of 50% orange crush Matonjeni launch of guava, passion, orange and tropical crushes aggressive in store activities for example Mohamed Musa

COMPANY SOCIAL RESPONSIBILITYSchweppes Zimbabwe Limited participates in a number of social responsibilities such as donating product, training of students during work related periods etc.SZL also gets quite a number or donations requests for various needs from various organizations. Categorically there are four main lines that the donations are channelled by the company and they are namely:

Sports and recreationSchweppes Zimbabwe Limited plays a pivotal role in the success of the annual Danhiko Project Paralympics games through the donation of Schweppes water and Mazoe orange crush. Trade Promotion and industry developmentThe company has in the past supported events such as the Confederation of Zimbabwes industries, HIFA, Harare Agricultural Show, and the Jaggers classics by donating money.

Education

Primary and secondary schools come to educational tours and among those are Eaglesvale Primary and College and St Georges College. There are supervisors who are responsible for educating student on tour. The company also has a Graduate trainee programme and a work related learning programme which gave the author an opportunity to learn. Charity

Vulnerable children as well as those that are living with HIV get donations from the company for their HIV camping and tournaments.

EXPECTATIONS AND INDUSTRY REALITYWhen the student got exposed to the new environment that is Schweppes Zimbabwe Ltd in October 2012, he had never been in any industry before. As a human being both excitement and nervousness caught up with him since he had many expectations. With what was offered in the industrial environment it differed from the expectations of the student. Some of his expectations were to be fulfilled to a greater extent than he had imagined or perceived. When the student started working he had a number of expectations and these are highlighted below: The author expected to be lonely at all times and to feel out of place he also expected to be assigned to do difficult experiments on his own to prove competence he thought that bosses would not interact nicely with subordinates and that they were mean he also expected that as a student on work related learning he would be tasked to sweep the floors and to do all other dirty jobs The author expected to see a state of the art laboratory without any apparatus amiss in it he also thought that he would have his own equipment to work with and own space

Expectation Gaps

Contrary to what the author had expected, all the things turned out to be different. The QA department was filled with supportive and caring people and the bosses were also very friendly unlike the initial belief that they would be mean. The student never felt lonely at any particular time and he wishes the work related learning period would be extendable. In the lab all the apparatus and equipment were used by the QA department team and no one was entitled to his/her own apparatus like the author had hoped for.The author was given fairly challenging assignments and he got overwhelming support in doing them from the workmates. The author did not even realize his lack of experience in the first part of the work related learning period because he was always assisted by others until able to stand on his own feet. The laboratory had ordinary equipment and some of the apparatus were yet to be bought/to replaced and during that period the author had to improvise in executing his duties. Some of the apparatus used are also available at college and they were quite familiar hence easier to utilize. The author also learnt that as a student he did have to sweep and do other dirty jobs that were not linked to his programme.

CHAPTER2

WORK RELATED LEARNING RELEVANCE TO DEGREE PROGRAMMEAN OVERVIEW OF THE DEPARTMENTS AT SCHWEPPESThe Production department encompasses bottling, packaging and manufacturing services. It is there for continuous, uninterrupted production. The production department is the main operating sector of the company and is supported mostly by all other departments. The QA laboratory provides part of the technical services as it provides testing and analytical services primarily to production. It constitutes the nub of the quality control function in the company and it provides services to the purchasing function (i.e. examination of raw materials). Procurement department carries out all purchases. Stores are responsible for the receipt and storage of raw materials and Packaging materials and other items of use to the company. The Stores department is again responsible for the issuing of materials to all departments in the company. The Warehouse is where the finished products are stored and collected for sale; it works hand in hand with Distribution department. Sales and marketing are the `sellers` or merchandisers and they receive customer complaints which are then brought to QA for analysis.

Finance is responsible for main budgets of the company and other accounting matters such as documentation, payment of bills, and control of incoming and outgoing cash flow .The Audit department undertakes all internal auditing of departments. The IT department develops and manages the ERP (Entity Resource Planning System), which is a Microsoft product that governs the entire business operation. The IT links all departments through information communication technology. The Human Resources department is concerned with the recruitment and selection of potential candidates and payrolls. Lastly the Engineering department is there to provide engineering project management, and maintenance services to the whole company.

THE QUALITY ASSURANCE, ENVIRONMENT, SAFETY AND HEALTH DEPARTMENTThe QEOSH department was the placement department and is divided into 4 sections which are (i) Analytical Laboratory (ii) Microbiology Laboratory (iii) Packaging Laboratory (iv) Quality Systems, and Safety Health and Environment and (v) Water Treatment.

The QA department at SZL ensures that a high quality product is produced, which meet the consumer expectations. It is involved in all processes which are related to maintaining and improving quality conformance, including systems approach for Quality Management. There are control procedures used which range from chemical tests, physical tests-visual inspection and microbiological tests. The department also seeks to quantify the impact of the business on the environment, and to address its impacts on the natural environment itself. It also deals with health and safety issues involving the worker, visitors and contractors. This is the department to which the student did his work related learning.

Fig2.1 QA Departmental structure

KEYQAE- Quality Assurance and EnvironmentSHE- Safety Health and Environment

Quality statement According to Coca-Cola, quality is more than something we see or measure or manage. It shows itself in every action and it encompasses everything we do from processing to packaging. Anything less than 100% is not acceptable because our consumers throughout the world deserve the highest quality beverages we can produce.

THE ROLES AND DUTIES OF THE DEPARTMENTProcess monitoring Analyse the product for acidity, brix colour, taste, appearance in comparison to other products. Check to ensure that the label is properly aligned on the bottle Check for proper date coding To ensure that all the required parameters are met by the products Standardization of test reagentsMicrobiology Media preparation for pour plating and membrane filtration Micro analysis of incoming raw materials Analysis of environmental swabs, equipment and final products

Packaging material analysis and inspection Monitoring all quality aspects associated with packaging material, PET pre-forms and blown bottles. Sampling and analysing all packaging materials from external suppliers. Conducting trials of packaging materials from suppliers. Handling and investigating consumer complaints, both internal and external. Conducting material age survey. Calibration and up keeping of Packaging laboratory equipment and records. Training of packaging personnel on Good Manufacturing Practices and Product handling.Equipment calibration and verification All the equipment used in the laboratory are calibrated and verified according to the manufacturers instructions, every day.

GOOD MANUFACTURING PRACTISES MONITORING (GMP)The quality of the products produced at Schweppes largely depends on the hygienic status of the production plants. This is achieved by GMPs. Plant hygiene is maintained at high standards at SZL and cleaning process ensures plant hygiene. This involves the removal of juice and syrup from pipelines using cold water and the cleaning fluid is introduced. The cleaning process involves the use of detergents which are available in liquid and powder forms; these include alkalis (caustic soda) and general purpose detergents for the floors.

The basic function of the detergents is establishing intimate conduct with the soiled matter through wetting, hydro toping effect, penetrating properties and displacement of soil. Detergents vary and their use depends on operation of the short pipe runs. Combination of detergents is also used to ensure efficient cleaning action. The cleaning methods employed at SZL are manual (for utensils), Cleaning-In-Place (CIP) for tanks and filling machines. The cleaning processes are done at the end or before every production run and several methods are used to assess the sanitary condition of processing equipment. These methods are: (i) Inspection of the cleaning and physical examination making use of senses of sight, smell and feel, (ii) Chemical examination which involves checking, using chemical tests the presence of detergents (caustic soda) in the rinsing water to detect if remaining residues of the chemicals, (iii) Bacterial examination in which microbial counts are done on plant surfaces processing equipment and packaging material.

GMPs are guidance that outlines the aspects of production and testing that can impact the quality of a product. Although there are a number of them, all guidelines follow a few basic principles. Manufacturing processes are clearly defined and controlled. All critical processes are validated to ensure consistency and compliance with specifications. Manufacturing processes are controlled, and any changes to the process are evaluated. Changes that have an impact on the quality of the food are validated as necessary. Instructions and procedures are written in clear and unambiguous language. Operators are trained to carry out and document procedures. Records are made, manually or by instruments, during manufacture that demonstrate that all the steps required by the defined procedures and instructions were in fact taken and that the quantity and quality of the food was as expected. Deviations are investigated and documented. Records of manufacture (including distribution) that enable the complete history of a batch to be traced are retained in a comprehensible and accessible form. The distribution of the food minimizes any risk to their quality. A system is available for recalling any batch of drug from sale or supply. Complaints about marketed foods are examined, the causes of quality defects are investigated, and appropriate measures are taken with respect to the defective drugs and to prevent recurrence.

Inspection of Raw MaterialsThis section refers to the inspection of goods received by the Stores department. These raw materials include; food ingredients such as juice, sugar and essence (units), packaging materials and other materials used for production processes. The raw materials were received together with Certificates of Analysis (COAs) then these COAs were given to the quality inspector. Upon the COAs, the student was instructed to inspect the material received. On inspection the student had to take note of the material name, manufacturer, batch number and the expiration date provided by the manufacturer if it complied with the COAs. Samples were then taken of the materials so that they could be tested in the laboratory. With use of the reference documents and Standard Operating Procedures (SOPs) for testing of materials, the samples were tested against the set specifications of KOKE. Chemical, microbiological and organoleptic tests were conducted on food ingredients, visual and measurements conducted for packaging materials.

Fig2: 2Flow diagram of examination of raw materials

PROCESS CONTROLProcess control describes the monitoring and control of a process to ensure that it operates at its full potential to produce conforming products. The process control involved monitoring of water treatment, syrup preparation, packaging material and line inspection of bottling lines. On-the-spot tests were carried out during food processing to measure (often indirectly) composition and the physical properties of food products. Rapid feedbacks were essential during process control to ensure that adjustments could be made in time to maintain product quality. During process control chemical, physical, visual and organoleptic tests were carried out. The chemical tests incorporated alkalinity determination in water, clinistix test in water, caustic concentration of detergent solution test and sulphur dioxide determination in cordials. The physical tests involved those in which instruments were used for analysis, for example weight and torque. Visual and organoleptic tests incorporated the use of the five senses to analyse the products. In the course of process control there had to be receipt of a sample form from the originating section stating the product name, quantity of sample, samplers name, time and date of sampling, and the test parameters and their specifications. There was then verification of specifications provided before sample analysis. The acquired results were recorded on the sample form and the sample form was returned to the originator. The operations carried out during process control are shown in the next page.

Fig 2.3: Diagram on operations employed during process control

PRODUCT EXAMINATIONThe product examination process is not entirely control but it helps to confirm that the desired product results have been attained. Product examination mainly encompasses product organoleptic acceptability, and some other chemical, microbiological and quantitative tests. During this process, representative samples were drawn or taken from the production lines. The first consideration during product examination was total dissolved solids (brix) which had to fall between the set limits provided. Other tests would follow after brix measurement; these were foreign material, torque, and fill height. Analysis was then followed by recording documentation of check sheets.

Fig 2.4: Flow diagram on product examination

ANALYSIS DONE IN THE ANALYTICAL LABORATORYSugar analysisA 1kg sample of sugar was taken with a scoop from the tonne bags of sugar being analysed. About 82g of sugar was weighed and distilled water was added and stirred. When the sugar had dissolved, turbidity was determined. Turbidity is the clarity of a solution/fluid, its cloudiness or haziness. The brix was measured using the refractometer and had to be between 50-60 degrees. Sugar was tasted after diluting 20ml in 100ml of treated water. There was an odour test for sugar also done. In the Odour After Acidification test, phosphoric acid was added to 100ml of sugar solution with the pH meter dipped to ensure the pH reading reached 1,5 . The sample was then heated while swirling gently, sniffing the solution after every 10 minutes for a period of 30 minutes to note if there are any unusual odours. After analysis all results are recorded in the Sugar analysis file.

Juice analysisSamples were taken aseptically from every batch that was received. Colour, sweetness (taste), odour and appearance were observed to see if they conformed. Brix was measured using the refractometer and had to be 50 degrees or more. To get acidity, 10g of juice were measured and 100ml of distilled water was added, the sample with a magnetic stirrer was put on the auto titrater to get the titratable acidity. Using the titratable acidity, the corrected brix was obtained from Brix Tables. The results were then recorded in the Juice analysis file.Units were not analysed as per requirement of Coca Cola but their packaging was inspected for any breakages, storage requirements and also the date codes were checked.PH determinationDetermination of pH value of products or raw materials pH denotes the measure of acidity or alkalinity of a solution. The test was done with use of a pH meter equipped with a glass electrode (probe) connected to an electronic meter that measures and displays the pH reading. The pH meter was calibrated at the beginning of each working day. The calibration was carried out with the use of two buffer solutions, pH 4 and pH 7 buffer solutions.

Fig 2.5 Picture showing a hand held pH meter

Brix (Solids) Determination Refractometer MethodThis method is intended to determine the percentage of solids or sweeteners using a Refractometer. The Brix scale measures the amount of sugars in solutions and determines the amount of solids in products where sugar is the main component, such as in fruit juices, fruit pulps and syrups. A small amount of sample is put on the Refractometer prism surface; the Brix (%) is then read directly from the instrument. For syrups, the Density and Sound Velocity meter was used to measure brix. Its a complex and advanced machine through which syrup passes through membranes.

Alkalinity of Water testThis method is used to determine the alkalinity level of water samples. Alkalinity is a solutions capacity to neutralize an acid. When determining alkalinity phenolphthalein was used as colour indicator, the water turns pink if the pH is above 8.3. When determining alkalinity using methyl orange or methyl purple the water samples turns yellow and green respectively if the pH is 4.9.The water sample is titrated with sulphuric acid, after some addition of sodium thio-sulphate which neutralizes any chlorine present and 3 to 4 drops of phenolphthalein indicator and a stirrer. The volume of acid used is recorded and multiplied by 10 to get (P) alkalinity (mg/l as CaCO3).The titration is continued using methyl orange or purple. The volume used during both titrations is multiplied by 10 to get (M) total alkalinity.

Sulphur DioxidePreservatives can be categorized into three general types: antimicrobials that inhibit growth of bacteria, yeasts, or moulds; antioxidants that slow air oxidation of fats and lipids, which leads to rancidity; and a third type that blocks the natural ripening and enzymatic processes that continue to occur in food stuffs after harvest. Sulphur dioxide serves all three functions, which is one reason why it and related compounds called sulphites are found in so many household products .A small percentage of the population is allergic to sulphites but the majority of the population is safe. In addition to its antimicrobial action, sulphur dioxide inhibits degradation reactions in fruits, thus consequently juice. The procedure is as follows: 1. Take 25ml of sample with clean 25ml bulb pipette into 250ml conical flask.2. Add 2-3 drops of starch indicator into the sample.3. Titrate against 0.1 Iodine solution.4. The end point will be when you observe the first permanent blue-black colour5. Record the reading from the burette.Calculation:Titrate value x Iodine factor (result after standardization) = Result (mg/L)

TorqueTorque, also called moment of force, is the tendency of a force to rotate an object about an axis fulcrum, or pivot. Just as a force is a push or a pull, a torque can be thought of as a twist. Loosely speaking, torque is a measure of the turning force on an object such as a bolt or a flywheel. For example, pushing or pulling the handle of a wrench connected to a nut or bolt produces a torque (turning force) that loosens or tightens the nut or bolt. A torque is an influence which tends to change the rotational motion of an object. The torque meter was used to check if the capper had applied the closures within the recommended range of 9-17. The spring torque tester was used at SLZ.

Caustic Concentration of Detergent Solution Detergents used in Cleaning In Place (CIP) at SZL industry are of known concentration/strength, this enables efficient and economic use of these detergents. Use of detergents with a weaker strengths result in poor cleaning regimes, whilst highly concentrated detergents results in unnecessary loss of detergents as well as corrosion to rubber rings in joining pipes. Alkaline detergents are generically known as caustics and chemically they are NaOH (caustic soda). They are used in the sanitation process. Acid detergents used react with mineral deposits that have accumulated on juice contact surfaces. Juice and mineral deposits become hardened and layered on the equipment surface and provide excellent surfaces on which biofilms, which are adherent macro-colonies of bacteria, may thrive. Acids are used in proper strengths to attack all these without attacking rubber parts.To test caustic concentration 10ml of the detergent solution was obtained and put into a beaker, 2-3 drops of P indicator were added and the sample was titrated using 1N sulphuric acid. The sample was titrated until a pink colour disappeared and the solution was colourless for at least 20 seconds. Volume of acid used was recorded as P value. Two to three drops of M indicator were added and titration was continued until green to greyish purple. Volume used in both titrations was recorded as the M value. Calculations are as follows: 2P-M =A % NaOH =A x 0.4

Ozone Residual Water test Maintaining the optimum level of ozone is very critical. If the ozone level is too high, plastic bottles may develop an after taste. If the ozone level is too low bacteria spores hidden in the water, inside the plastics walls of closure devices can recover and easily contaminate the entire products. The procedure quantifies the ozone residual in water sample whenever ozone is used as disinfectant. A small sample of ozonated water containing a DPD pill was placed in a comparator and the comparator was held towards a light source and a colour disc could be rotated until it matches in the two windows. The concentration was read in mg/l and appropriate action could be taken if results did not meet the required specification.

Net contentA balance scale was used to measure the net content of products according to their specifications. When they are out of spec they are then put on hold so that a way forward may be determined.

Visual and Observation testsThe other tests include foreign matter which uses light to see if there is foreign matter in water and for other drinks direct observation is done. Label application and date code also used direct observation to see if the label is being applied correctly on the correct product and if the date code is correct. The date code shows the best before date, the time and the line were it was produced this helps in traceability programs.

Iodine StandardizationThis was necessary for the Iodometric titration of sulphur dioxide. The method is as follows:1. Measure 5 ml of Sodium Thiosulphate2. Add 2 drops of Starch indicator3. Titrate with iodine solution4. Divide titre volume by 640 to get iodine value

Residual Chlorine test A digital colorimeter is the most accurate way to measure free chlorine and/or total chlorine residual and this was used at SZL. The colorimeter used the following method: 1) Addition of DPD tablets or powder into a vial of sample water that causes a colour change to pink2) Insertion of the vial into a meter that reads the intensity of the colour change by emitting a wavelength of light and automatically determining and displaying the colour intensity (the free and/or total chlorine residual) digitally. The range of the meter was 0 - 4 mg/L, equivalent to 0 - 4 ppm (parts per million).

ANALYSIS IN THE MICROBIOLOGY LABORATORY

Microbiology is the science study of the microscopic forms of life which can be found in the environment (Soper, 1997). These microorganisms include bacteria, moulds, yeasts, algae, protozoa and viruses. Most microorganisms are unicellular, with some consisting of loose aggregate of independent cells and some form long filaments or protoplasts within a single cell wall. Microorganisms perform the same fundamental activities within their single cells as higher organisms do within their many celled structures, and this is the basis of microorganism studies. Microorganisms are ubiquitous, meaning they are found everywhere, in soil, bodies of water, in the food and water we consume and even in the air we breathe, the mouth, nose, digestive tract and other human body regions. Due to the above mentioned areas of microbiological growth, tests were done on products, water, raw materials, equipment or plant environment and work personnel.

Yeast and MouldsYeast cells (single cell organisms of spherical, elliptical or cylindrical shape) are undesirable organisms in the beverage industry as they cause fermentation products with formation of gas and acid (Merck, 2003). The gas produced results in the blowing off of fermented and sweetened products while the acid formed gives the product a bitter taste which is undesirable and renders the product unfit for human consumption. Optimum pH growth for yeast growth is 4, 5 to 5, 0. Yeast cells are facultative anaerobes, in the absence of oxygen they breakdown sugar to alcohol and water, while in the absence of oxygen they break down sugar into carbon dioxide. The micro-organisms can cause defects in orange juice and orange juice products and syrups.

Fig2.7: Showing Yeast Cells Yeast can develop as white, pink, red, or green colonies with a satiny or shiny appearance. Other colours of yeast colonies also exist.

Non-fluffy appearance Fluffy appearance Fig 2.8: Showing mouldsMoulds can form many different colours. Some of these colonies can have a fluffy appearance.

COLI FORM DETERMINATIONThe coli form test is a more specific bacteriological test for the quality of non-carbonated products. It is used as an indicator of proper sanitation. Coli forms are defined as all aerobic and facultative anaerobic, Gram positive, asporogenous rods able to ferment lactose with the production of acid and gas. These organisms constitute a threat to safety of beverage products because they indicate a potential to cause disease out breaks. Faecal coli forms are a division of coli forms that are distinguished by their ability to ferment products with the production of acid and gas at elevated temperatures (43-45C). E-coli are faecal coli forms because of the presence of E-coli in humans and animal intestine and in their resultant stools. Its presence in processed foods is generally considered to indicate pollution of direct or indicate faecal origin. The Total coli form method has two stages: The presumptive test Confirmed testIn the presumptive test, series of McConkey fermentation tubes are inoculated with decimal dilution of the samples, formation of gas and acid after 24-48 hours at 37C constitute a positive test.For the confirmed test, decimally diluted samples are inoculated into tubes containing Blue Green bile, which contains selective and inhibitive agents that suppress the growth of all coli form micro-organisms accept faecal. Gas and acid production at elevated temperature of 442C constitutes a positive test for faecal contamination.

Total Bacterial Count (TBC)Juice and juice products are a good media for bacterial due to their nutritive values. There are four main sources of high TBCs in juice and juice products and these are as follows: Environmental contamination such as poor hygiene/ WRONG procedures used is sanitizing the preparation tanks. Bottling equipment Poor storage of the product Juice extractionTotal Bacterial Counts are also applied to non-juice products such as syrups and Schweppes still water, in which case they are used as a measure of the purity of the product as well as of the effectiveness of the sanitation regime being put in place. High TBC in juice and non-juice products lead to product of poor quality and also shortens the life span of the products.

Fig2.9: Showing Total bacterial Growth

GOOD LABORATORY PRACTICESA microbiology analysis is all about accuracy and to attain accuracy there has to be employment of good laboratory practices (GLP). When there is use of GLP, aseptic techniques are employed during, before and after analysis. This comprises of cleaning and disinfection of workbench before and after analysis, and cleaning and disinfection of the plating room before and after use. SZL used 70% alcohol for disinfection of workbench and hands. Sterilization of pipettes, media, diluents, and decontamination of lab waste was also crucial as exposure could bias results. All cultures and other materials had to be made non-infectious before disposal from the lab thus used Petri dishes were autoclaved first before disposal to clinical waste. The microbiology waste was placed in plastic bags which were securely sealed and sent for incineration. Other methods of disinfection included autoclaving pipettes, glassware, and using chemical disinfectants such chlorine.Elimination of residue through the drain is strictly forbidden as the chemicals cannot be reduced by waste water plants and hence there would be contamination of the environment. Sterilization by autoclaving was done for 15minutes at 121C to achieve sterility of glassware and other apparatus. Components of a GLP as stated to the author are shown below;1) Laboratory coats or correct protective clothing should be worn at all times2) All glassware to be used for analysis should be sterile3) All organisms examined to be handled as carefully as possible and must be treated as potentially infective4) Test tubes holding cultures should always be kept standing on racks5) Cultures meant to be incubated should be labelled accurately and adequately ( with name of test material, dilution, culture used and date of incubation) before incubation or storage at the appropriate place in the lab6) Media and live cultures are never to be poured down the drain as they may clog the drains due to setting7) Sterilization of loops, tongs and forceps before and after inoculation is a necessity8) Always check incubation temperatures (log them on the temperature log sheet), sterilization temperatures, and water bath temperatures9) Always calibrate scale either in the morning or before use and record on the internal scale calibration file10) No eating/ food in the micro lab

MEDIA PREPARATIONA culture medium is a substrate or nutrient rich solution which is used for the cultivation of microorganisms. Culture media was prepared from dehydrated powders which were rehydrated using de-ionized water and mixed with the use of a hotplate magnetic stirrer. Depending on the preparation instructions, some were heated until they reached boiling point and some were not exposed to heat during stirring. The media was then sterilized with use of an autoclave. Exposure of media for 15 minutes to usually temperatures of 121C is enough to destroy all organisms which might hinder accuracy of the process. Agars mainly used at SZL were m-GYM (Green yeast and moulds), PCA (Plate Count Agar), PDA (Potato Dextrose Agar) and others. OSA (Orange Serum Agar), m-Endo and m-TGE. OSA is mainly used in culturing acid tolerant microorganisms and is optimally adapted to special requirements of microbial flora present in citrus juices because it contains orange extracts and a pH of 5.5 0.2 at 25C. PCA is mainly used for microbial counts and has a pH of 7 0.2 at 25C. PDA however has a pH of 5.6 0.2 at 25C and is used for cultivation of yeasts and molds because the carbohydrate and potato infusion promotes growth of yeasts and molds while low pH inhibits growth of accompanying bacterial flora, (Merck,2003)

PLATING TECHNIQUESAfter sufficient dilution of samples, the inoculums were added to the specified culture mediums. Two techniques were mainly used, pour plate and membrane filtration.Pour plate methodWith use of a Bunsen burner, the sample was aseptically transferred to a properly labelled and sterile Petri dish. The aseptic transfer was achieved through exposing the tip of the pipette to the flame, cooling and then sucking the diluted sample. The author was instructed to only open the Petri dish enough to allow the tip of the pipette to go through and avoid contamination from aerial microorganisms. Molten agar was then poured after inoculation of sample into the Petri dish, approximately 10 15ml of the agar was used. The bottle containing the agar was flamed before and after pouring the agar to achieve and maintain asepsis. The Petri dish was then swirled in an anticlockwise and clockwise direction, five times each and left to set before being incubated in an inverted position.

Membrane filtrationMembrane filtration involved filtration using liquid or dehydrated media pads and solid media in Petri dishes. A sterile membrane apparatus was attached to a vacuum source. Forceps were dipped in alcohol and flamed and were used to aseptically place a sterile membrane filter into the apparatus. After sample dilution, it was aseptically poured into the top of the apparatus. The vacuum was applied to draw the sample through the membrane after which the cover was removed and the sample was rinsed with sterile water. The liquid was drawn and flamed forceps were used to remove the membrane to a sterile Petri dish with proper media. The sample was then incubated at the appropriate temperatures for a proper duration. (www.microbio.com/biologicssafetytesting,14-04-2013)

ANALYSIS DONE IN PACKAGING LABORATORYRaw materials used in packaging of the product are analyzed (i.e) labels, corrugated slip pads and closures were analyzed physically for compliance with Standards and Certificate of Analysis. Shrink-wrap, liners and stretch wrap were analyzed for dimension, thickness and conformance to COA. Pre-forms used in bottle blow molding are also analyzed for conformance to COA and weight as well as ability to work with appropriate closure. Blow molded bottles are analyzed for clarity, sectional weight and wall thickness. Packaging analysts are also responsible for monitoring process of PET blow-molding at correct temperatures and pressure.

QUALITY SYSTEMS KNOWLEDGE AND IMPLEMENTATION SKILLSThe company has stringent programs, standards, guidelines and operating procedures, built from KORE, ISO 9001:2008, ISO 22000:2005, SAZ 749 and PAS 220:2008, to ensure that all their products are safe. The company recently attained a Standards Association of Zimbabwe (SAZ) certificate which focused on the implementation of the ISO 22000:2005 of Food Safety Quality Management System.

KORE stands for Coca Cola operating requirements. It provides a management system foundation that combines discipline toward producing the highest quality product while allowing flexibility to achieve global implementation. KORE offers assurance in quality, food safety, environment and Occupational health &safety. To strengthen this assurance SZL align with external, internationally recognized standard. KOKEFRAMEWORK

KORE has 5 levels:i) Policiesii) Standardsiii) Specifications iv) Requirements v) References The first four make up the WHAT, they focus on the desired outcome rather than the process. The final level makes up the HOW or the manner in which the KORE requirements can be achieved.

POLICIESThe policy level is the foundation upon which the entire management system is built. The policies state the Companys expectations & they guide the activities &decision making of the organization .SZL has 4 policies Quality: confirming the coca cola systems strong commitment to quality in all that is done Food safety: stating our adherence to proven food safety systems, processes and controls Environment: strengthening our position as environment leaders OHS: reaffirming that people are our most valuable resources

STANDARDSThe company is aligned with internationally recognized standards in manufacturing, production & distribution as part of our commitment to global governance & operational excellence. Because global customers expectations are constantly evolving, SZL have aligned with international and industry standards to stay current with the highest level of Quality, environment, safety and health. SZL is certified to:i. ISO 9001:2008ii. ISO 22 000: 2005 & HACCPiii. OHSAS 18001:2007iv. ISO 14001:2004

SPECIFICATIONSProvide prescribed limits or characteristics to which a product or service must conform. Specifications provide parameters used to monitor measure & analyse a product to ensure it conforms with & meets the necessary quality requirements.i. Beverage & product specificationsii. Ingredient specificationsiii. Packaging, sales & marketing equipment specifications

REQUIREMENTSIncludes the company requirements needed to protect trademark & product integrity& to ensure protection of people & the environment. Provide the details of what must be implemented and the desired output:i. Beverage & product requirementsii. Facility environment& safety & health requirementsiii. Standard methodsiv. Packaging requirementsv. Sales & marketing equipment requirements

REFERANCESRepresents the How in the KORE frameworki. Referencesii. Guides & guidelinesiii. Procedures

PRODUCTION PROCESS AT SCHWEPPES

The production department is the main operating sector of the company and is supported mostly by all other departments. It constitute of the following departments:i) Manufacturing Services Department ii) Packaging Department. The QAE provided part of the technical services as it offered testing and analytical services primarily to production.

MANUFACTURING SERVICES DEPARTMENTThis department comprises of sub-sections which are Water Treatment, Simple Syrup Room and Final Syrup Room. Each sub-section is responsible for providing services for production purposes. The Water Treatment is responsible for management, treatment and monitoring of incoming water from municipal, to ensure that water meets the specifications for its intended use. The Simple and Final Syrup Rooms are responsible in the production of all the non-carbonated beverages. These products were brought for testing to the QA department before bottling commences.

WATER TREATMENTThe process is done to proactively manage, treat and monitor incoming water (municipal water) to ensure that water meets the specifications for its intended use. The procedure applies to the Water Treatment Plant and it starts from raw water analysis, tank filling, chemical dosing, coagulation, filtration and final analysis to release for use. Portable water (municipal water) is used as raw water for the multi-barrier water treatment system. The multi-barrier system consists of:1. Treatment tanks covered on top1. Sand filter and flow meters1. Semi-treated water tanks 1. Carbon filters and flow meters 1. Polishing filters- with 10 micron filters1. Backwashing water storage tank for potable reuse. Potable reuse is obtained by blending recovered water with raw water at no more than 20% by volume. The water passes through sand and carbon filters before it is fed to treatment water tanks for a full chemical treatment.The sand filters and carbon filters are backwashed every 24 hours if the water analysis results for sand/carbon filters are out of specification. For Packaged Water it is further treated by reverse osmosis and ozonation after the multi-barrier treatment. Treated water that has passed through the multi-barrier treatment is used for:1. Cleaning and sanitation of product-contact equipment1. Manufacturing of products1. Rinsing of containers on line

Fig3.1: Water treatment flow diagram

WATER TREATMENT FLOW DIAGRAMThe flow diagram shows the whole process of water treatment before use in the plant. Lime is added to stabilize the pH, ferrous sulphate encourages sedimentation and coagulation and chlorine destroys bacteria. The sand filters trap residues (dirt), lime and the ferrous sulphate. Carbon filters trap the chlorine and this is the first critical point because chlorine tends to bleach or discolour products. The polishing filters further purify the water as it passes through cartridges before it is transferred to the plant. For packaged still water, the water undergoes a process known as Reverse osmosis. Reverse osmosis is a process by which a solvent such as water is purified of solutes by being forced through a semi-permeable membrane against its concentration gradient, the solvent passes but not solutes. The water is then transferred to the final syrup tank were salts are added. The tank is agitated and the water is filtered. A process known as ozonation then occurs where a gas known as ozone is put in the water to preserve it for the next 9 months shelf life.

HOMOGENIZATION OF JUICEHomogenization is the act of making something uniform by blending together thoroughly so as to get a homogenous composition. The juice is mixed with the orange oil until they are homogenous and this process prevents separation. Orange peel oil is added to concentrate to mask and slow down the development of a card board off-taste during storage. The homogenized juice is used in the in Mazoe orange crush, and Mazoe orange light.

Fig3.2: Homogenization Flow Diagram

SIMPLE SYRUP The simple syrup refers to the dissolved sugar which should have a brix range of 50-60 degrees. Brix is the amounts of sugar in solution. Pre-checks were done to ensure if the contimol, mixing tank, sieves and filter were properly sanitized. The following flow diagram shows the whole process of simple syrup preparation.

Fig 3.3: Simple syrup Flow diagrams

BTA means buffer tank. Water is added into the dissolving tank, in sufficient quantity to cover the jet mixer. The water starts circulating and the sugar valve is then opened. The screw conveyor moves the sugar from the Hooper to the dissolving tanks. After dissolving of sugar it is then transferred to the simple syrup buffer tanks. These are numbered to help when doing traceability. The total soluble solid (brix) is then tested with reference to the sugar tables. Appropriate final syrup personnel are informed that the simple syrup is ready for filtration and the simple syrup is transferred to the final syrup room.

FINAL SYRUPThe final syrup room is where all the final products are prepared. Pre-checks are done to ensure all tanks and pipes are sanitized. The final syrup tank and ingredient mixing tank are sanitized to eliminate possible health hazards arising from pathogenic microorganisms associated with syrups. Before the simple syrup is transferred to final syrup room, the quantity of the granulated sugar required is calculated, based on the product mixing instructions. Brix of the simple syrup is tested and the volume is determined by reading from the slighter glass. The simple syrup is filtrated through a sieve before it reaches the final syrup tanks. Filtration is done to remove any foreign material that maybe found in the syrup. The pressure of the syrup is also monitored during the simple syrup transfer. Simple syrup checks are carried out. The tests will be on brix, temperature, sweetness, odour and temperature, based on the specifications required. If they are out of specification, alterations are made. Dissolved ingredients and water are added to the simple syrup and agitated. The process of agitation enables the mixing of the syrup and other dissolved ingredients. Agitation carries on up until all ingredients are thoroughly mixed to homogeneity level. When the syrup is ready it is tested for Brix, temperature, taste, odour and acidity as per required specifications. The final syrup is also tested on appearance in comparison with the reference sample. The reference serves as the control, syrup is then released after it is confirmed that it is ready for bottling. The following flow chart shows all the processes done in the final syrup room.

Fig3. 4: Final syrup Flow DiagramPACKAGING PLANTThe packaging plant is where the containers/bottles are made from resin to pre-forms and then the pre-forms are blown to produce bottles. Coca-Cola approved resin is used in the manufacture of the various pre-form sizes and the lot numbers of the resin used are captured on production log sheets. The preforms are stored in boxes with plastic liners to prevent dust and foreign particles and these boxes are allocated lot numbers which appear on the box sticker. The preforms are kept under the stores department for 48 hours before blowing to allow uniform cooling. All the scrap from the perform manufacture is disposed.The Quality Assurance Department approved pre-forms are used for bottle blowing and the lot numbers of the pre-forms used are captured on the production log sheets for record keeping. The bottles are stored in boxes with plastics liners to prevent dust particles .These boxes are allocated lot numbers which appear on the box stickers and on lot number log sheets. The whole process is shown by the following diagram

Fig3. 5: Bottle manufacture Flow diagram

BOTTLING PLANT The bottling plant is where the finished beverages conforming to quality requirements, meeting customer and consumer expectations are packaged for the market. Bottles from the packaging plant are fed into the bottling process through the unscrambler and sorted out and conveyed to the filler by an air conveyor. The bottles are rinsed to remove any foreign material before filling; this prevents any form of contamination. The containers are filled up to the specified fill height to avoid over or under filling. In the case of packaged water filling, ozone levels are checked on hourly basis, on the ozone monitor to maintain the optimum level required during bottling.

Filled containers are capped with the designated colour of closure for the particular product. The QA checks the torque on capped product. The checks are done after a certain period of time to make sure all the bottles are being closed properly. Capped products are labelled according to the type of syrup. The labeller operator sets the date coding machine accordingly and frequently monitors the print on the product for any deviations. No products go to warehouse without proper date coding. Finished products are shrink-wrapped to the particular case size for easy handling and storage. The flow chart is as follows:

Fig 3. 6: Bottling Flow diagram

WAREHOUSEThe warehouse is where the finished products are stored before distribution to the market. The pallets are stacked in racks and bays. The flow diagram simply shows what happens in the warehouse.

Fig 3.7: Warehouse Flow Diagram

HOT FILL PROCESSHot Filling is a proven and recognized method for filling high acid foods (pH less than 4.6) that will be shelf stable at ambient temperatures. This method is used extensively in the food industry for filling a glass and plastic containers and in paperboard cartons. It relies on heat treatment to temperatures in the region of 194-203 F (90-95 C) for at least 15 seconds (typically 15-30s). This process produces a Commercially Sterile Product by killing all microorganisms capable of growing in it. The product is then cooled and filled at temperatures ranging 180-185 F (82-85 C) into containers, sealed immediately with closures, and then held at this temperature for approximately 2-3 min. The hot filling will sterilize the inner surface of the container. The filled containers are usually placed on their sides so that the neck-finish and closure are also sterilized. The containers are then cooled in a cooling tunnel in order to minimize the thermal degradation of the product.The main purpose of hot filling is to provide a product free from microorganisms capable of growing in it at ambient storage. Commercial sterility or thermally processed food refers to the absence of disease-causing microorganisms, absence of toxic substances and of spoilage-causing microorganisms capable of multiplication under a number of non-refrigerated storage and distribution conditions. The same line runs cold filled still water that is ozonated to microorganisms.

CHAPTER 3

PERSONAL AND PROFESSIONAL DEVELOPMENT

The knowledge acquired at college before the work related learning helped the author a lot as he found it simple to relate the theory and the practical work during the work related learning period. There was now a better meaning to why certain tests are carried out in the laboratory. For example when you test for acidity on the face value of it its just an acid base titration but at Schweppes we carried the acidity to determine preservative concentration and taste.The author also leant administrative and business skills as he realized that when running a business every variable like water usage and electricity consumption counts as it impacts on the final financial gain of the company. Another major aspect leant was to minimize errors as a small error could ruin the financial outcome of the company as a simple customer return would mean transport to go and fetch the product back from the market and also money to destroy it .During the work related learning period the author was able to identify his strengths and weaknesses with the former outweighing the latter.

Strengths

Confidence- this is the major strength that the author had and he was always confident thanks to the stronger theoretical knowledge he had leant and college. Communication-because of the exceptional staff that the author worked with, he always found it easy to communicate with any of them. Responsibility- the author was very responsible because he knew that any lack of concentration would make everything go wrong and that would land him in big trouble. Time management- he always found it easy to prioritize things in order of importance and at the end of the day his work was well outlined, traceable and neat.

Weaknesses Entrance- upon entering the company some people would look down upon the author as they saw him as a mere student who could offer nothing and this pulled him down. Slow adaptation to adjustments- the author was slow to adapt to the fact that he was expected to work on night shifts as it was new to him. Short temperedness- he had problems in dealing with workmates in the production area as some of them didnt want to listen to him as he was the QA personnel to assure that quality is maintained a top priority at all times.

Keys skills developed

Technical skill

The author leant to aseptically collect samples and to plate using aseptic techniques. He also learnt how to effectively titrate samples and to make calculations based on the titrations. Implementation of international systems was another thing that the author leant as well as the importance of HACCP and the environmental occupational health and safety (EOSH). Interpersonal skillsThe author realized how communication is an important tool in the success of a company as it brings individuals to a common platform for decision making, mutual understanding, conflict resolution and exchange of ideas. Business skillsAs some of the information was confidential the author had to learn to be integral and maintain the ethical value of the confidentiality. Time management was also another key aspect of business that the author leant as time is considered as money in business terms. Management of costs was also a major highlight as far as the business skilled acquired by the author are concerned.

RECOMMENDATIONS AND CONCLUSIONS

Limitations A lot of bottling Stoppages and interruptions could be observed during production, This was mostly due to the increased breakdown of machines during operation.Raw materials could come contaminated due to weather conditions, during transit which could lead to cross-contamination of products.At times storage space was inadequate for product being produced; this led to products being stored between production lines.Observation of the first in first out (FIFO) rule was not totally adhered to due to overloading of the raw materials in the stores department.The increased power cuts had a negative impact on all plant operations and on the keeping quality of product resulting in major financial losses.Sensory evaluations were not properly conducted for new products developed.Some employees were reluctant to practice; GMPs this could lead to contamination of products.

RecommendationsLine stoppages that have an impact on food safety and quality of product should be handled in such manner as to prevent product contamination or spoilage. Line interruptions or stoppages that last more than 60 minutes, normal QA product tests should be carried out on samples from either the filler bowl or Syrup room tanks before bottling resumption. There should be strict maintenance requirements for all processing equipment to ensure conformance of that equipment in producing/processing productsThere should be a sensory evaluation laboratory for the purpose of testing new products developed by Research and Development department.All incoming raw materials should be tested for the presence of inhibitors which could cause cross contaminationAll employees should receive documented training in personal hygiene, GMPs, cleaning and sanitation procedures and personal safety.

CONCLUSIONThe Work Related learning year has made the student to mature personally, academically, professionally and socially. It was a good first time industrial experience working at SZL and It has made him discover that working environment is different from college environment. He would like to thank everyone who made his stay a pleasant one. Nevertheless, he adopted mature ways of self-conduct, professional etiquette as well as good communication skills. The student is of the opinion that industrial attachment is a very important tool in equipping undergraduate students with professional experience. Going through work related learning is absolutely an eye opener and experience of a lifetime; he managed to effectively amalgamate and integrate the learnt theories and concepts with the practical demands of industry. He managed to quickly synchronize the theory he had learnt at college into relevant practice especially pertaining to networking, operating systems and internet.

References

1) Merck OP (2003),MERCKS MICROBIOLOGICAL METHODS AND TECHNIQUES MANUAL,12TH EDITION, Logic Printers Inc, Germany

2) Soper R, (1997),BIOLOGICAL SCIENCES,3RD EDITION, Cambridge University, UK

3) www.microbio.com/biologicssafetytesting 14-04-2013Joel T T TaruzaPage 1

Start

1. Tank Filling

3. AgitationFor 5-10 mins

2. Chemical Dosing

A.Municipal Water or 80% Municipal & 20% backwashing water

B.LimeC.HTH-ChlorineD.Ferrous Sulphate

8. Polishing Filtration10 micron pore size

7. Carbon filtration

9. Transfer of treated water

F. Granular Activated Carbon

E. Sand

4. Settling Minimum 4 Hours

Backwashing Water Tank

Sand Filtration

6. Semi-treated water storage

Carbon Filtration

Polishing Filtration

CCP 1

G. 10 um filter bag

Treated Water toSimple Syrup Final SyrupMazoe LightBottlingPackaged WaterMazoe RTD

INPUTS

PROCESSES

OUTPUTS

10. BACKWASHING

5. Sand filtration

Start

2.Mixing Mix orange juice and orange oil in drum

A.Orange ConcentrateB.Orange Oil

4. HomogenisationHomogenise for 30 mins at 45-50 m/s

3. Transfer of juice to homogenising tank

1.Prechecks on drums & orange oil glass jars

5. Transfer of homogenised juice

Homogenised orange juce to : Final Syrup

Mazoe Light

Mazoe RTD

End

INPUTS

PROCESSES

OUTPUTS

start

B.Treated water

4. Sugar dissolving

2. Dump sugar into hopper

9. Release to final syrup

6. Dissolved sugar filtration cartridge & filter bag

7.Simple syrup storage BTA 2

3. Sugar transfer into mixing tank

End

8. Simple Syrup Filtration 100 mesh

5.dissoved sugar storage BTA 1

low brix sugar

1.Weighing and Cleaning of sugar bags

C. Filter CartridgeD. Filter bag

C. Filter

Simple syrup toFinal Syrup

A. Sugar

INPUTS

PROCESSES

OUTPUTS

End

A. Simple Syrup B. Homogenized Juice C. Treated Water D. Additives ( Beverage Base)

4.Transfer to Bottling

1.Ingredient Addition

2.Agitation

Testing & verificationacidity, brix & colour

Start

3.Filtration15/100 mesh(refer to mixing Instructions)

Final syrup to Bottling

Dearation30 mins

INPUTS

PROCESSES

OUTPUT

CLEANING WASTE WATER

low brix

Start

2. Resin pre-heating(dehumidifying,150-160degC, 5 hrs)

4. Injection moulding(mould cooling 7degC)

1. Feed resin(vacuum suction)

5. Preform packaging(food grade plastic liners)

F. Compressed Air40 bars

3. Plasticisation(backpressure 10-20bars,290degC)

8. Preform pre-heating(2 heating zones, 130-170degC)

E. Preforms

B. Plastic Liners, C. BoxesD. Labels

9. Blow moulding(mould cooling 14degC,)

7. Feed Preforms(clean cartons and machine hopper)

10. Packaging of bottles(food grade plastic liners)

Resin bags

End

B. Plastic Liners, C. BoxesD. Labels

6. Preform Temporary Storage(not more than 6 months)

11. Bottle Storage(ambient conditions,enclosed area)

INPUTS

PROCESSES

A. Resin

Molten PET lumps

Worn out boxes,liners, Preform rejects

reject preforms and bottles

OUTPUTS

Blown Bottles to Bottling

N

S

E

W

start

6. Labelling

1. Bottle Feeding (hopper, unscrambler)

7. Date coding

8. Shrink wrapping

2. Air conveying

C. Treated WaterWater Treatment

9. Palletising

11. Transfer to warehouse

10. Stretch wrapping

D. Final syrup

B. Compressed Air 10 bar(filtered)

F. Labels

End

3. Bottle rinsing

H. Date Coding Ink

I. Shrink film

J. PalletsPallet sheets

K. Stretch Film

E. Closures

A. PET BottlesBottle Manufacturing

Finished ProductWarehouse

G. Glue

INPUTS

4. Filling

PROCESSES

OUTPUTS

Waste water

Plastic

Plastic

5. Capping

Start

1. Pallet Receiving

2. Stacking and Storage

Finished Product

3. Picking

4. Loading into trucks

End

INPUTS

PROCESSES

A. Finished product

OUTPUTS