beverages industry

i

CHEMICAL PROCESS TECHNOLOGY

SEMESTER PROJECT | GROUP NO 6

Beverage Industry

(Carbonated Drinks)

Ammar Hussain, Hassam Wajahat, Osama Hasan,

Oun Hasan Syed, Zainab Mazhar, Zohair Ahmed

Spring ‘10

Instructor

Dr. Noaman ul Haq

School of Chemical and Materials Engineering (SCME)

National University of Sciences and Technology (NUST)

H-12 Campus, Islamabad

i

Summary

The article paper focuses on the evolution of carbonated drinks dating

back to fourteenth century. It also discusses the effect of technological

revolution, it variations over decades and challenges and development in

Pakistan.

Further it focuses on the raw materials used in the industry, their quality

and sources, followed by the processing of the raw materials and the

process that lead to the final product i.e. carbonated drink

The report also includes a survey showing the demand of the product.

A list of brands and companies doing business in Pakistan is also given in

appendix.

ii

Acknowledgements

We are thankful to Almighty Allah for His unlimited blessings and bounties;

for keeping us sane, sound and successful,

Our parents for all their support and trust in us,

Our Instructor Dr. Noaman ul Haq, for all his guidance and appreciation,

Engr. Muhammad Asif (Coca Cola Beverages Pakistan Limited) and

Mr. Iftikhar Ahmad (Riaz Bottlers Private Limited),

for all their support and coordination

and all our teachers, friends and colleagues for their help in completion of

this report.

iii

Table of Contents

SUMMARY ....................................................................................................................................................... I

ACKNOWLEDGEMENTS .................................................................................................................................... II

TABLE OF CONTENTS ...................................................................................................................................... III

LIST OF FIGURES .............................................................................................................................................. V

LIST OF TABLES ............................................................................................................................................... VI

1 INTRODUCTION ....................................................................................................................................... 1

1.1 Evolution of Beverages and Carbonates ...................................................................................................... 1

2 BEVERAGE INDUSTRY .............................................................................................................................. 2

2.1 Consumption Patterns of Beverages ............................................................................................................ 2

2.2 Advancement in Carbonates Production ..................................................................................................... 3

2.3 Technological Development ......................................................................................................................... 3

2.4 Rise in Demand ............................................................................................................................................ 4

2.5 Challenges and Perceptions ......................................................................................................................... 4

2.6 Beverage Industry in Pakistan ...................................................................................................................... 5

2.6.1 Slower Growth with Decreasing Purchasing Power ................................................................................. 5

2.6.2 Increasing Consumption of Diet Products and Bottled Water ................................................................. 5

2.6.3 PepsiCo Inc Remains Market Leader with New Product Launches .......................................................... 6

2.6.4 Increasing Purchases at Department Stores and Discounters ................................................................. 6

2.6.5 Steady Growth with Stiff Competition ..................................................................................................... 6

3 THE SURVEY ............................................................................................................................................ 7

4 RAW MATERIALS ..................................................................................................................................... 8

4.1 Basic Raw Materials ..................................................................................................................................... 8

4.1.1 Water ....................................................................................................................................................... 8

4.1.2 Sugar ........................................................................................................................................................ 8

4.1.3 Acids ......................................................................................................................................................... 8

4.1.4 Emulsions ................................................................................................................................................. 8

4.1.5 Saponins ................................................................................................................................................... 8

4.1.6 Additives .................................................................................................................................................. 9

4.1.7 Flavorings ................................................................................................................................................. 9

4.1.8 Preservatives ............................................................................................................................................ 9

4.1.9 Chlorine .................................................................................................................................................... 9

5 INDUSTRIAL PROCESSING OF BEVERAGES ............................................................................................... 10

5.1 Production of Beverages ............................................................................................................................ 10

5.2 Water Treatment ....................................................................................................................................... 10

5.2.1 Water Sources ........................................................................................................................................ 11

5.2.2 Water Treatment ................................................................................................................................... 11

5.2.3 Sand Filtration ........................................................................................................................................ 11

5.2.4 Coagulation ............................................................................................................................................ 12

5.2.5 Alkalinity Reduction ............................................................................................................................... 12

iv 5.2.6 Membrane Filtration .............................................................................................................................. 12

5.2.7 Chlorination ........................................................................................................................................... 13

5.2.8 Iron Removal .......................................................................................................................................... 13

5.2.9 Nitrate Removal ..................................................................................................................................... 14

5.2.10 Water Polishing ................................................................................................................................. 14

5.2.11 U.V Systems ....................................................................................................................................... 14

5.2.12 Ozone technology .............................................................................................................................. 14

5.2.13 De-aeration ........................................................................................................................................ 14

5.3 Syrup Preparation ...................................................................................................................................... 14

5.4 Carbon dioxide and Carbonation ............................................................................................................... 15

5.4.1 Commercial Production of Carbon dioxide............................................................................................. 15

5.4.2 Recovery from Flue Gas ......................................................................................................................... 16

5.5 Modern Filling Systems .............................................................................................................................. 16

5.5.1 Modern Carbonation Systems ................................................................................................................ 17

5.5.2 Counter Pressure Fillers.......................................................................................................................... 17

5.5.3 Glass Bottle Filling .................................................................................................................................. 18

5.5.4 PET Bottles ............................................................................................................................................. 18

5.6 Can Filling ................................................................................................................................................... 18

6 EQUIPMENT AND MACHINERY ............................................................................................................... 19

7 ENVIRONMENTAL ISSUES ...................................................................................................................... 20

8 HEALTH AND SAFETY ............................................................................................................................. 22

8.1 The Food Safety Management System (FSMS) .......................................................................................... 22

8.1.1 Policy ...................................................................................................................................................... 22

8.1.2 HACCP .................................................................................................................................................... 22

BIBLIOGRAPHY .............................................................................................................................................. 25

APPENDIX A .................................................................................................................................................... A

APPENDIX B .................................................................................................................................................... D

APPENDIX C .................................................................................................................................................... E

v

List of Figures

Figure 1 Consumption Patterns of Beverages in US (2008) (Dolcera, 2009) .................................. 2

Figure 2 Survey Results for Baverage Patterns (NUST) ................................................................... 6

Figure 3 Survey Breakups for Baverage Patterns (NUST) ............................................................... 7

Figure 4 Beverage Production Cycle ............................................................................................. 10

Figure 5 Water Treatment Process ............................................................................................... 11

Figure 6 Syrup Manufacture Process ............................................................................................ 15

Figure 7 Recovery of CO2 from flue gas ........................................................................................ 16

Figure 8 Group photo with our mentor from ccbpl ........................................................................ d

Figure 9 group photo with our mentors from RBL, Lahore ............................................................ e

vi

List of Tables

Table 1 The Types of Beverages (Wikipedia®, 2010) ..................................................................... 1

Table 2 Annual Beverage Consumption in USA (2008) (Dolcera, 2009) ......................................... 2

Table 3 Production lines AT Coca-Cola Beverages Pakistan Limited (Lahore).............................. 19

Table 4 Production Lines at Riaz Bottler’s (Private) Limited......................................................... 19

Table 5 List of PakistaniBeverage Brands (Jamal's, 2008) .............................................................. a

1

1 Introduction

1.1 Evolution of Beverages and Carbonates Water is an essential need of the human body. Most of the biological functions are based on

appropriate consumptions of water per day (eight glasses for a normal human being). Its

shortage (Dehydration) leads to problems like malfunctioning of kidney and excretion problems

etc. Beverages were developed as an alternate to meet the body’s fundamental requirement

for hydration. A classification list of beverages is given in Table 1.

Prior to twentieth century, European cities were highly affected from cholera, dysentery and

other waterborne illnesses. Contaminated with several micro-organisms, water was hazardous.

Therefore Barley waters, Lemonades and orangeades were used to fulfill body’s hydration

requirement.

Scientific development and considerable investigations on gases paved way towards

carbonated drinks. Joseph Priestley (who is widely credited for discovery of oxygen) dissolved

carbon dioxide in water under pressures to produce carbonated waters artificially.

Commercially, mineral waters were the first beverage product to hit market followed by

carbonated drinks synonymous with “aerated mineral water”.

The first commercial artificially carbonated water product dates back to late eighteenth century

(Steen, 2006). Recommended for the consumption of lemon juice and soda water for stomach,

it was sold in tightly corked glass bottles.

Early effervescent drinks were manufactured by mixing sodium bicarbonate solution with

lemon juice or lime juice. This mixture can cure scurvy and therefore became a very strong

reason for its use in on board a ship. Thus were used for medicinal pedigree to a greater or

lesser extent. Examples include quinine tonic water, used as a cure for malaria in tropical

regions. (Steen, 2006)

TABLE 1 THE TYPES OF BEVERAGES (WIKIPEDIA®, 2010)

Types of Beverages Examples

Alcoholic Beer, Champagne etc

Non Alcoholic Low Alcohol beer, non-alcoholic wine, apple cider etc

Soft Drinks Carbonated Drinks, Lemonade, Squash, fruit juices, squashes etc

Cold Beverages Milkshakes, Iced Tea, Cold Coffee etc

Hot Beverages Tea, Coffee, Hot Chocolate etc

Others Buttermilk, Soup, Yogurt etc

2 Beverage Industry

2.1 Consumption Patterns of BeveragesThe average annual beverage consumption of US population as per according to the

Beverages Market Research Handbook

TABLE 2 ANNUAL BEVERAGE CONS

Carbonated Soft Drinks

Bottled Water

Tap Water

Beer

Coffee

Milk

Fruit Beverages

Tea

Wine

Distilled Spirits

FIGURE 1 CONSUMPTION

Coffee, 11.24

Milk, 10.87

Fruit

Beverages, 6.

97

Beverage Industry

Consumption Patterns of Beverages annual beverage consumption of US population as per according to the

Beverages Market Research Handbook is as under:

ANNUAL BEVERAGE CONSUMPTION IN USA (2008) (DOLCERA, 2009)

Annual Beverage Consumption

Beverage Percentage

Carbonated Soft Drinks 26.22

Bottled Water 14.36

Tap Water 13

Beer 11.34

Coffee 11.24

Milk 10.87

Fruit Beverages 6.97

Tea 4.11

Wine 1.14

Distilled Spirits 0.73

CONSUMPTION PATTERNS OF BEVERAGES IN US (2008) (DOLCERA, 2009)

Carbonated

Soft

Drinks, 26.22

Bottled

Water, 14.36

Tap Water, 13Beer, 11.34

Coffee, 11.24

Milk, 10.87

Fruit

Beverages, 6.

97

Tea, 4.11

Wine , 1.14

Distilled

Spirits, 0.73

2

annual beverage consumption of US population as per according to the 2008

(DOLCERA, 2009)

(DOLCERA, 2009)

Carbonated

Drinks, 26.22

Bottled

Water, 14.36

3

2.2 Advancement in Carbonates Production The Industrial Revolution gave new life to the production of carbonates. A process of

continuous development was made and implemented. Several patents and trademarks were

filed and registered and a new boom was driven. The per unit production in mid nineteenth

century varied from 100 dozen bottles per day to 300 dozen bottles per day from manual to

steam powered units.

Near the end of nineteenth century, most of the common carbonated soft drinks of today were

already on sale. Dr. John S. Pemberton combined Cola (or Kola; was a nut from West Africa

which was used by Nigerians as a symbol of hospitality) and Coca (an extract from South

American coca leaf) to produce Coca-Cola or ‘brain tonic’ (Coca-Cola, 2010). Near the same

time, Pepsi-Cola was launched by Caleb D. Bradham. (Steen, 2006) (Pepsi, 2010)

2.3 Technological Development In early eighteenth century it was evident that brewery fermentation, wood combustion and

acid addition to marble/chalk resulted in the production of same gas. Initially, the most widely

implemented means of commercial production was by the action of sulphuric acid on marble

chippings. Crushed marble was cheap and readily available in bulk quantities. But low quality of

marble resulted in noticeable ‘off flavors’ in the finished drinks. Therefore manufacturers

introduce filters and scrubbers to remove taints. Bubbling of the produced gas through olive oil

was also practiced for removing organic taints. This increased the cost and later was replaced

marble chippings were replaced by sodium bicarbonate.

Sweeteners proved to be the drivers for growth of carbonate industry. Saccharin was a popular

sweetener for carbonates, usually blended (50-50) with sugar for cost reduction. With

popularity of low calorie carbonates, a blend of 1 part saccharin to 10 parts cyclamate produced

a good tasting low calorie sweetener system. Saccharin leaves an unpleasant bitter after taste

when used as a sole sweetener. The quantity of carbon dioxide in a carbonated drink has a

pronounced affect upon its character and flavor impact.

Initially, naturally carbonated waters were collect into earthen ware containers, which were

tightly sealed with cork and wax. The failure occurred when highly carbonated waters reacted

with the material and thus caused a replacement by glass bottles. These glass bottles initially

were hand blown and needed a skilled labor. The glass bottles were firstly sealed with wooden

corks which later were replaced with screw stoppers and finally crown corks.

The main factor which played a significant role in the expansion of carbonate industry in the

latter half of the twentieth century was technology. This is evident from the development of

cans, plastic bottles and improvements in the distribution systems. With the introduction of

railways and steam ships in 1800’s the transport of drinks was made very easy. As time passed,

4

trade expanded to vaster regions which added to the cost. To reduce this trade was considered

on a local scale. The number of companies has reduced greatly to reduce the cost and this is

evident as it is now under 100 which are lesser than the initial 400. (Steen, 2006)

In a similar manner to avoid costs the number of bottling plants have also reduced quite

drastically from an impressive 7000 to roughly around 3500m, with more stress on recycling

plants. This is due to the improved productivity. PE bottles are now being recycled to improve

the efficiency and productivity. Other means of improving productivity consists of using shrink

wraps instead of crates or boxes, using micro processor controlled equipment, using automatic

machines in preference to manual power, a centralized computer controlled system and an

automatic tracing system.

2.4 Rise in Demand The growth of carbonates has not only increased in the west but this trend has also reached in

Asia in countries like china as well as reaching south-East Asia in the subcontinent in India.

Carbonates have dominated the soft drink market and the carbonates market is dominated by

cola. In 2004, the scale of carbonate consumption internationally was a massive 193,000 million

liters. However, research conducted shows that in the recent times the number of carbonates

produced are on the decline.

Three factors contributed largely to the popularity of the carbonates and these included:

marketing, lifestyle and technology. The use of powerful images to advertise their brands have

interested the public significantly. This has further been supplemented by the easily availability

of carbonated drinks. With advancement in technology, the result has led greatly to cost

savings. As cans and bottles are recycled raw material is saved. Use of automatic machinery has

further aided this process making it cost effective. An interesting statistic tells us that in 1998

the price of carbonated drinks fell by 1% in the UK despite the inflation being 12% (Steen,

2006). This was only possible due to the awareness of saving the costs and the introduction of

the modern technology.

2.5 Challenges and Perceptions Despite the success of modern carbonated drinks an increased hostility and a concern is raised

amongst the people. Environmentalists consider the packaging of carbonated drinks as a source

of waste and litter adding to the pollution. Other serious concerns have resulted recently with

an increase in carbonated drinks which are focused and shown by the media. These include

obesity (especially in children). The carbonated drinks are considered as “junk food”. Most of

the ailments are thought to be caused because of a carbonated drink. Many countries are

taking steps of banning carbonated drinks altogether from schools. Another research has

proven that excessive intake of carbonated drinks cause disruptive behavior in a child and

reduces his learning abilities. Another theory states that the intake of carbon dioxide in the

5

body affects the calcium which is an essential element of the body and thus has serious

consequences on the bone density and structure. Many anti carbonated drinks campaigns are

taking place in various countries of the world. Due to these reasons figures have shown that

carbonated drinks in the recent times have reduced significantly while sales of diet drinks,

juices and water are on a rise.

As time has evolved low calorie carbonates are being produced. Now artificial sweeteners are

used in place of sugars which reduce the chances of serious diseases that can have severe

consequences on the human body like diabetes In the future it is expected that this trend will

be followed and number of carbonated drinks will reduce and substituent like mineral water or

juices will raise considerably.

2.6 Beverage Industry in Pakistan The beverage industry in Pakistan has grown over the time. The industry produces soft drinks,

juices, syrups, milk, and squashes. With about 170 units currently in operation throughout the

country, both upstream and downstream industries have grown and are flourishing (Ahmed,

2003). Pakistan’s soft drinks industry is set to experience volume sales growth of 30.5% till

2010. (Business Wire, 2007)

Beverages, the second largest segment consists of various brands of tea. Beverages share in net

sales and operating profit during 2008 was at 32% and 18%, respectively. Net sales of the

segment posted a healthy growth of 22% in 2008 to PKR 9.6 billion. Sharp increase of 24% in

Kenyan tea prices as well as depreciation of domestic currency reduced the margins of the

segment to 23% in 2008 from 28% in 2007. Lipton is the key brand in beverages segment of

Unilever Pakistan. A leading carbonated drink brand has its annual sale up to 175-180 million

crates. (First Capital Equities Ltd, 2010)

2.6.1 Slower Growth with Decreasing Purchasing Power The economic crisis hit Pakistan hard, and the consumer purchasing power dropped

significantly. Carbonated drinks volume growth slowed down due to increasing poverty, and

rising unit prices have also put downward pressure on volume growth. Competition has

increased with the wide availability of imported products and additional products from local

manufacturers. (Euromonitor International, 2009)

2.6.2 Increasing Consumption of Diet Products and Bottled Water Consumer demand for ‘diet’ products has increased. New products from international

companies which are major share holders in carbonates have been well received and imported

products in the juices category have also attracted a lot of consumer attention. On the other

hand, bottled water consumption has increased with the deteriorating water supply in urban

areas and increasing health consciousness. (Euromonitor International, 2009)

2.6.3 PepsiCo Inc R

Launches PepsiCo Inc has introduced new diet product that has been well received and supported by

good marketing activities. This new launch

market and prove to be tough competition for Diet

lead from Nestle by offering 100% concentrate products across the country. Bottling companies

are facing stiff competition from local unregistered companies that sell a

class, urban areas. (Pepsi, 2010)

2.6.4 Increasing Purchases at Department store chains are aggressively opening up branches in different areas of the country.

This gives consumers a choice, but creates a competitive environment for

manufacturers. With rising poverty and reduced disposable income, people prefer to shop at

government-owned discount stores and big department stores that give discounts on bu

purchases. Distribution has reached the rural

companies are searching for new areas where they can increase their market shares.

(Euromonitor International, 2009)

2.6.5 Steady Growth with During the forecast period increasing competition with new innovative products and more

imports will see the consumption rate grow at a good pace, but unit price growth will be slower

as the overall poverty level increases in the country. This will in turn, slow

Distribution to more rural areas is likely to improve. Companies will introduce innovative new

products in order to retain their share in the competition against imported products.


A survey was carried out by the team to observe the trends for preferences of beverages.

Following results were observed:

FIGURE 2

Drink

18%

Remains Market Leader with

PepsiCo Inc has introduced new diet product that has been well received and supported by

good marketing activities. This new launch will help PepsiCo Inc to increase its share in the

and prove to be tough competition for Diet Coke. Juices manufacturers have taken their


are facing stiff competition from local unregistered companies that sell at cheap prices in lower

(Pepsi, 2010) (Euromonitor International, 2009)

urchases at Department Stores and Department store chains are aggressively opening up branches in different areas of the country.

consumers a choice, but creates a competitive environment for

poverty and reduced disposable income, people prefer to shop at

owned discount stores and big department stores that give discounts on bu

purchases. Distribution has reached the rural areas, especially in terms of juices, because



rowth with Stiff Competition the forecast period increasing competition with new innovative products and more


as the overall poverty level increases in the country. This will in turn, slow




out by the team to observe the trends for preferences of beverages.

Following results were observed:

2 SURVEY RESULTS FOR BAVERAGE PATTERNS (NUST)

Fruit Juice

60%Drink

18%

Milk

22%

Beverage Priorities

6

eader with New Product

PepsiCo Inc has introduced new diet product that has been well received and supported by

will help PepsiCo Inc to increase its share in the

Coke. Juices manufacturers have taken their


t cheap prices in lower

tores and Discounters Department store chains are aggressively opening up branches in different areas of the country.

consumers a choice, but creates a competitive environment for carbonated drinks

poverty and reduced disposable income, people prefer to shop at

owned discount stores and big department stores that give discounts on bulk

areas, especially in terms of juices, because


the forecast period increasing competition with new innovative products and more


as the overall poverty level increases in the country. This will in turn, slow down value growth.



out by the team to observe the trends for preferences of beverages.

ST)

3 The Survey

Why turnover of carbonated water industry is more even though

juices?

Stats revealed that overall 60% of people from all age groups preferred fruit juices as their first

priority of a beverage. Despite this the turnover of carbonated water is more than that of the

fruit juices. There are several factors behind this abnormal trend. The reasons are as follows:

� Carbonated water is preferably the most served drink in the festive occasions of our

culture such as marriages, parties and other public gatherings.

� Sub continental food being spicier re

� The soft drink industries use the technique of marketing to attract consumers especially

amongst the younger generations who when attracted to such advertisements instantly

go and buy the products.

Thus the soft drink industry has more turnover than the juice industry despite the people

preferring juice over the carbonated water

FIGURE 3

0%

10%

20%

30%

40%

50%

60%

70%

80%

Female below 25 Male below 25

Why turnover of carbonated water industry is more even though most people prefer fruit



veral factors behind this abnormal trend. The reasons are as follows:

Carbonated water is preferably the most served drink in the festive occasions of our

culture such as marriages, parties and other public gatherings.

Sub continental food being spicier requires a carbonated drink to aid in digestion.

The soft drink industries use the technique of marketing to attract consumers especially


go and buy the products.

oft drink industry has more turnover than the juice industry despite the people

preferring juice over the carbonated water, in our survey done by the authors.

SURVEY BREAKUPS FOR BAVERAGE PATTERNS (NUST)

Male below 25 Female above 25 Male above 25

7

most people prefer fruit



veral factors behind this abnormal trend. The reasons are as follows:

Carbonated water is preferably the most served drink in the festive occasions of our

quires a carbonated drink to aid in digestion.

The soft drink industries use the technique of marketing to attract consumers especially


oft drink industry has more turnover than the juice industry despite the people

n our survey done by the authors. (Ahmed, 2003)

(NUST)

Male above 25

Fruit Juice

Drink

Milk

8

4 Raw Materials

4.1 Basic Raw Materials The basic raw materials in a carbonated beverage industry are:

• Water

• Sugar Syrup

• Concentrate

• Carbon Dioxide

4.1.1 Water

It is water which is made carbonated by the addition of carbon dioxide gas under pressure.

Carbon dioxide and water form carbonic acid. Commercial soda water in siphons is made by

chilling filtered plain water to 8 degrees Celsius, adding sodium or potassium based alkaline

compound such as sodium bicarbonate to reduce acidity, and then pressurizing the water with

carbon dioxide, known as Carbonation. The gas dissolves in the water, and a top-off fill of

carbon dioxide is added to finally pressurize the siphon to approximately 120 psi (pounds per

square inch), some 30 or 40 psi higher than is present in fermenting champagne bottles. Soda

water is often manufactured on-site using devices known as carbonators. Carbonators utilize

filtered water and pressurize it to approximately 100 psi using mechanical pumps. The

pressurized water is stored in stainless steel vessels and CO2 is injected into the water

producing carbonated water. (Sof)

4.1.2 Sugar Sugar makes up 7-12% of a soft drink. Sugar adds sweetness and body to the beverage. Sugar

also balances flavor and acids. High-intensity sweeteners are combined with sugar and other

sweeteners and flavors to improve the beverage.

4.1.3 Acids Acids add sharpness to the background taste. The most common acid used is citric acid. Acid

also reduces ph level.

4.1.4 Emulsions They are added to carbonated drinks primarily to enhance “eye appeal” by serving as clouding

agents. Emulsions are mixtures of liquids that are normally incompatible. They consist of water-

based elements, such as gums, pectins, and preservatives; and oil-based liquids, such as flavors,

colors, and weighing agents.

4.1.5 Saponins

9

They enhance the foamy head of certain carbonated drinks, like cream soda and ginger beer.

4.1.6 Additives They enhance taste, mouth-feel, aroma, and appearance of the beverage.

4.1.7 Flavorings

They may be natural, natural identical (chemically synthesized imitations), or artificial

(chemically unrelated to natural flavors). It also provides the required smell or fragrance.

4.1.8 Preservatives

In order to stop the growth of microorganisms and prevent deterioration, preservatives are

added. Anti-oxidants, such as BHA and ascorbic acid, maintain color and flavor.

4.1.9 Chlorine Impurities in the water are removed through a process of coagulation, filtration, and

chlorination. Coagulation involves mixing floc into the water to absorb suspended particles. The

water is then poured through a sand filter to remove fine particles of Roc. To sterilize the

water, small amounts of chlorine are added to the water and filtered out.

10

5 Industrial Processing of Beverages

5.1 Production of Beverages The production of the beverages starts from the preparation of simple syrup (solution of sugar

and water). In other words, the simple syrup is prepared by making a solution of sugar and

water; the combined product is well stirred in the mixing machine with the aid of agitator. The

simple syrup is then taken via pipes into another mixing machine in the compartment called

“Syrup Room”. Here the syrup is added to concentrate in order to prepare the refined syrup.

The addition of simple syrup and the concentrate gives the soft drink otherwise known as the

beverage. The type of the concentrate (flavor) added to the simple syrup gives the

corresponding beverage. The final beverage is prepared by diluting the mixture with

carbonated water and then bottled.

Prior to the bottling of the carbonated beverage, the bottles are subjected to through

sanitation processes; the carbonated beverage is filled accordingly into the bottles of various

volumes. Subsequently, the bottles are corked, labeled and stored into crates.

FIGURE 4 BEVERAGE PRODUCTION CYCLE

5.2 Water Treatment All carbonated drinks contain 90% of water. Thus, the quality of water used in a soft drink must

be the same for each bottle of a drink in order to meet the international standards. As water is

the main constituent in a carbonated drinks; hence, the taste of a drink relies heavily on the

quantity of water that is being used. In order to maintain the high standards of a beverage

industry, the water has to go through a number of quality tests and processes before being

used in a beverage. There is always a risk to the consumers and the business, if a low quality or

contaminated water is used in a beverage manufacturing.

Water is famously known as a universal solvent. It can dissolve almost anything, from industrial

chimney sulphur to soil contaminants. During the hydrological cycle, water picks up such

Water Purification Sugar Syrup

ConcentrateCarbonationBottling

constituents and gets contaminated. It is therefore required to first clean the water before

using it as a solvent. Hence wat

Each company has its own method of water treatment which depends on their individual

standards. These methods have been developed after several trial and error methods.

5.2.1 Water Sources Town main streams are major sources of industrial use water. However, there are multiple

underground water sources as well. It totally depends on the availability of each respective

source as to which one is used by a beverage industry. Economics play a major role

choosing a water source.

Boreholes are a source of underground water supply. They provide very consistent water

quality that too at a constant temperature. Additionally boring water is more supportive for

carbonation, which is a major process at a b

5.2.2 Water TreatmentWater irrespective of the source has to meet the company’s standards. Thus, water treatment

is done at a large scale. Firstly, Sand filtration is done to remove any insoluble particulates in

water followed by the process of Carbon Filtration which removes any organic matter from

water. These are the two most basic water treatment methods which are generally adopted by

every beverage industry. Later, water polishing is done to remove cryptosporidium. Hardness of

water is removed by any of the three coagulation, ultra

Filtration or Ion exchange methods

done to kill any bacteria, viruses or moulds in water. This is followed by

removes any chlorine traces present in water. Finally, water is disinfected by passing Ultra

Violet (UV) light through it.

5.2.3 Sand Filtration A typical sand filter comprises

are five to six valves in a sand filter. Lateral pipes are installed just below the gravel.

Sand Filtration Carbon Filtration

Ultra Violet


using it as a solvent. Hence water treatment carries great significance in a beverage industry.



streams are major sources of industrial use water. However, there are multiple


source as to which one is used by a beverage industry. Economics play a major role



carbonation, which is a major process at a beverage industry.

Water Treatment Water irrespective of the source has to meet the company’s standards. Thus, water treatment


process of Carbon Filtration which removes any organic matter from



of the three coagulation, ultra-filtration or ion exchange. Ultra

methods are preferred by modern industries. Later, chlorination is

done to kill any bacteria, viruses or moulds in water. This is followed by carbon filtration, which

removes any chlorine traces present in water. Finally, water is disinfected by passing Ultra

FIGURE 5 WATER TREATMENT PROCESS

A typical sand filter comprises of a carbon steel vessel containing a sand bed of gravel. There

are five to six valves in a sand filter. Lateral pipes are installed just below the gravel.

Carbon Filtration Polishing

Carbon FiltrationUltra Violet

Filtration

11


er treatment carries great significance in a beverage industry.



streams are major sources of industrial use water. However, there are multiple


source as to which one is used by a beverage industry. Economics play a major role while



Water irrespective of the source has to meet the company’s standards. Thus, water treatment


process of Carbon Filtration which removes any organic matter from



filtration or ion exchange. Ultra-

are preferred by modern industries. Later, chlorination is

carbon filtration, which

removes any chlorine traces present in water. Finally, water is disinfected by passing Ultra-

of a carbon steel vessel containing a sand bed of gravel. There

are five to six valves in a sand filter. Lateral pipes are installed just below the gravel. Water is

Ultrafiltration

Chlorination

12

fed into the vessel from top, ensuring that it is distributed evenly through the sand bed, in

order to achieve better separation.

The solid impurities are held back in the sand bed while the water is allowed to pass through

the bed. For maintenance purpose the sand bed needs to be backwashed, later. This removes

the collected impurities of water from the bed and ensures better efficiency of the sand bed.

This is done on weekly basis.

5.2.3.1 Specifications of a Sand filter

For a 20m3/h vessel, 330kg of graded sand is placed on top of an 1800kg gravel bed. Five valves

are placed that are operated either automatically or manually, according to the need. For

cleaning the bed the filter is equipped with a pressure relief vent. It allows back washing of the

bed to remove collected impurities. To avoid contamination steel pipes are used in the sand

filter.

5.2.4 Coagulation Colloids are fine particles present in suspensions. They have opposite charges which prevent

them from coalescing together and make them more difficult to separate them from a solution.

Silts, Viruses and Color causing particles are all examples of colloids.

By the process of Coagulation such impurities are removed from water. An electrolyte is added

to water, this causes these oppositely charged particles to flock and eventually settle down in a

suspension. Aluminum Sulphate is a famous electrolyte used for coagulation process. Ferric

Chloride can also be used as an alternate. Known amount of electrolyte is added to know

volumetric flow rate of water to produce sludge. Special care needs to be taken while deciding

the amount of electrolyte being added to water, because excess electrolyte may increase the

turbidity of water. After adding the electrolyte the solution is mixed for 30 minutes. Then the

flocks are removed by a weir. Hydrating lime is added, to control the pH of water.

5.2.5 Alkalinity Reduction Alkalinity directly affects the taste of the carbonated drinks. Usually, the higher the alkalinity

of water the butter its taste is. Alkalinity is related to the hardness of water as well. Metallic

ions such as calcium and magnesium are primarily responsible for the hardness of water. Ion

exchange technique is adopted to reduce the alkalinity of water.

5.2.6 Membrane Filtration A membrane is a semi permeable barrier between two solvents that allows only certain

particles to pass through, thus causing separation. Transport through a membrane is achieved

due to electrical, potential, concentration, pressure or chemical differences. The flow

containing components retained in the filter is called Retenate flow. While the component that

passes through the membrane is called Permeate flow.

13

Raw water is fed through the membrane where it only allows smaller particles and ions to pass

through it. Most large colloids get separated because they cannot pass through the minute

sieves of the membrane. To reduce the burden on membrane, the water is first passed through

a filter to remove large colloids. Three types of systems exist; Reverse Osmosis, Nano-filteration

and Ultra-filtration. Ultra-Filtration removes 1000 molecular weight organic matter. It can be

used instead of Coagulation.

Nano-filtration is done at a lower scale. It is adopted specially for salty water where reverse

osmosis is ineffective. It can remove hardness, bacteria, viruses and other organic

contaminants. It has lower operating cost and can very well be used in place of Salt softening

technology.

Reverse Osmosis is the most efficient method of water purification, as it can remove anything.

It is based on the principle of semi permeable membrane. Between each membrane layer there

is a mesh separator. A pre-treatment is always required to remove water’s turbidity. It is also

used to meet the Bio-chemical oxidation demand.

Carbon filtration is always done before membrane separation to remove any metal ions present

in water. Metals ions such as calcium, magnesium and chlorine can easily blind the membrane.

They may block the flow of passing water.

With the period of time membrane gets inefficient and its efficiency of filtration decreases.

Then cleaning of membrane is required. This is done by recirculation of water with a cleaning

agent through the membrane for an hour. Reverse osmosis systems are cleaned by sterilizing it

under U.V systems. After maintenance a membrane works at 90% efficiency. The operating cost

depends on three factors Labor, Power and Chemistry.

5.2.7 Chlorination Chlorination discourages bacteria growth in water. Chlorine of known concentration is added to

water for a long period of time. Amount of chlorine to water needs to be monitored closely to

avoid any excessive use of chlorine. For this purpose a feedback control system is installed.

Liquid chlorine is preferably used instead of gaseous chlorine because it is more convenient and

the dosage can be controlled much more easily. After chlorination water is passed through a

carbon filter to remove any traces of chlorine.

5.2.8 Iron Removal Excess iron may discolor water to red, yellow or brown. At the same time it is essential for

transporting oxygen in water. Hence, optimum quantity of iron in water is 0.3 ppm. There are

two form of iron present in water; Soluble and Insoluble. Insoluble iron is first converted to

soluble iron by aeration or chlorination and then filtration is done to remove iron sludge in

water.

14

5.2.9 Nitrate Removal Nitrate content in water may cause corrosion in packed bottles and may also cause serious

illness among infants. Diseases like asthma and baby blue syndrome are common due to excess

nitrate content in water. Leaching, Sewage, Leakage in industries and wearing of rocks may lead

to high nitrate content in river water. Nitrates are highly soluble in water making it more

difficult to remove them from water. Usually, Ion exchange, Reverse osmosis, Distillation, Bio-

de Nitrification and Electro-dialysis are adopted for nitrate removal.

5.2.10 Water Polishing Filtration is used for polishing water. Carbon or Sand filters are generally used for this purpose.

For achieving greater polishing effect, polypropylene dept filters may be used. Another

alternative are filter bags, which have lower operating cost. Kalsep fibrotex unit can also be

used. It contains numerous fibers bundled together around a central core.

5.2.11 U.V Systems Ultra violet spectrum in light is an anti-bacterial agent. It can disinfect moulds, bacteria and

viruses. When U.V light from a source lamp passes through water it kills bacteria present in

water.

5.2.12 Ozone technology Ozone is capable of destroying bacteria, moulds, and other organic matter present in water. It

reacts with these species donating and oxygen hence restricting their growth. It can also

remove calcium, arsenic and other metal ions present in water. In order to purify water an

Ozone generator is utilized. Ozone level is measure via oxidation reduction potential meter or

with a direct read measurement in ppm. The later is preferred due to its accuracy. Additionally,

ozone can improve the taste of water and simultaneously reduce its hardness. Later, water is

passed through a carbon filter to remove any un-reacted ozone.

5.2.13 De-aeration

Usually, de-aeration plant reduces the amount of dissolved oxygen in water to <0.5ppm. This is

done to reduce the risk of deterioration in water.

Two main methods of de-aeration are Vacuum and Reflux or both. During the process water is

sprayed into a vacuum tank, and then it is pumped into another tank that is pre-filled with

carbon dioxide gas. This whole process is knows as Reflux de-aeration.

5.3 Syrup Preparation Syrup is one of the most important ingredients of the carbonated drinks. Syrup is simply a

mixture of sugar and water that is added to the drink to give it a sweet taste.

15

Sugars from the warehouse are placed in the sugar bunkers and are then transferred to the

dissolving tanks. In dissolving tank sugar is mixed with water at a temperature of about 85°C

and 800-1500 mPa pressure. The syrup is then transported to activated carbon tank where the

color and smell of the syrup is removed by the action of carbon. To remove the carbon present

in the syrup carbon filtration is done in hot pre-coat filter. The syrup is then transferred to

buffer tank and through heat exchanger (where its temperature is dropped to 15-20°C) the final

syrup is stored in the storage tank.

FIGURE 6 SYRUP MANUFACTURE PROCESS

5.4 Carbon dioxide and Carbonation As discussed before, Carbonated Drinks are combination of carbonated water and syrups.

Water is carbonated by passing carbon dioxide under pressure through water.

Discovered by Jan Baptist van Helmont, Carbon dioxide is a gas denser than air. It is colorless,

nontoxic and inert gas. Available at reasonable cost, carbon dioxide is virtually tasteless and

soluble in liquids forming carbonic acid. Its solubility increases as the liquid temperature

decreases.

5.4.1 Commercial Production of Carbon dioxide Carbon Dioxide, the major raw material of carbonated beverage industry, is commercially

produced by following processes:

• Combustion of Fuel Oil

• Recovery of Flue Gas

• Thermal Decomposition of Limestone

• Fermentation (as a byproduct)

• From Waste gas streams

• Membrane Separation

Sugar Warehouse

Sugar Bunker

Dissolving Tank

(80°C)Hot Pre-coat Tank

Reaction Tank

Activated Carbon Tank

Buffer Tank

Heat Exchanger

Storage Tank

(15 - 20°C)

5.4.2 Recovery from Flue GasFlue gases are the exhaust gases removed to atmosphere from a fireplace, oven, furnace, boiler

or steam generator. Combustion reaction is the main origin of flue gases. Compositions of flue

gases varies with the material being burnt, but it usually contains Nitrogen (more than two

third), Carbon dioxide, Water Vapor, Oxygen (in case of access air supply), and small ratios of

pollutants like Sulfur Dioxide, Nitrogen Oxides, Carbon Monoxides and particulate matter.

FIGURE

The recovery of carbon dioxide from flue gas is a multi stage process. The feed is flue gases

source either gas oil or natural gas fired steam boilers or a specially designed flue gas

production unit. The flue gas is first cooled using water spray (for higher e

the flue gas humidity) and then scrubbed to remove the unwanted particles. A Dry Scrubbing

System (Dry Sorbent Injection) is commonly employed. It involves the addition of an alkaline

material (Soda Ash in this case) into the gas st

The reactions results into formation of solid salts which are removed in the particulate control

devices.

5.5 Modern Filling In the modern era the filling systems for the carbonated beverages are based on

principles. Some factors have to be kept in mind when designing a filling system and these

include optimum performance during filling, high filling accuracy and preserving the maximum

product quality. Some factors have to be kept in mind which infl

product that is to be filled includes:

• Gas constituents present in the beverages

• Pressure during filling

• Temperature

• Viscosity

The most important consideration for effective filling of carbonated beverages are to maintain

the content, control the beverage temperature during filling and prevent the oxygen pick up.

Carbon dioxide must be prevented from coming out of the solution during filling by keeping a

fixed pressure of 1 bar which is higher than the saturation pressure for requir

Flue gas Condensation

Recovery from Flue Gas gases removed to atmosphere from a fireplace, oven, furnace, boiler



hird), Carbon dioxide, Water Vapor, Oxygen (in case of access air supply), and small ratios of


FIGURE 7 RECOVERY OF CO2 FROM FLUE GAS

ecovery of carbon dioxide from flue gas is a multi stage process. The feed is flue gases


production unit. The flue gas is first cooled using water spray (for higher e



material (Soda Ash in this case) into the gas stream to react with the acid gases (SO


illing Systems In the modern era the filling systems for the carbonated beverages are based on



product quality. Some factors have to be kept in mind which influence the quality of the

product that is to be filled includes:

Gas constituents present in the beverages


nt, control the beverage temperature during filling and prevent the oxygen pick up.


fixed pressure of 1 bar which is higher than the saturation pressure for requir

Condensation Scrubbing Absorption Stripping

16

gases removed to atmosphere from a fireplace, oven, furnace, boiler



hird), Carbon dioxide, Water Vapor, Oxygen (in case of access air supply), and small ratios of


ecovery of carbon dioxide from flue gas is a multi stage process. The feed is flue gases


production unit. The flue gas is first cooled using water spray (for higher efficiency by increasing



ream to react with the acid gases (SO2 or NOx).


In the modern era the filling systems for the carbonated beverages are based on simple



uence the quality of the


nt, control the beverage temperature during filling and prevent the oxygen pick up.


fixed pressure of 1 bar which is higher than the saturation pressure for required beverage

Stripping Carbon dioxide

17

carbon dioxide content. Care should be taken that the beverages are given sufficient amount of

time to settle prior to filling. If the precautions are taken it can have certain advantages and

these include:

• Carbon dioxide loss in the beverage is avoided

• Carbon dioxide consumption can accurately be adjusted

• The filling and settling times can be optimized

• Product losses are prevented

Despite carbon dioxide content of the beverage which has a major effect on the performance

and economics of the filling process oxygen maintenance also plays a role in the preservation of

the beverage quality. Oxygen pick up in the beverages must be controlled. Pressure plays an

important role because it depends on the required carbon dioxide of the beverage. The correct

pressure prevents carbon dioxide from coming out of the solution. Temperature is also an

important parameter because at lower temperatures carbon dioxide solubility is better. Due to

these factors the gas consumption is reduced and thus adds to economics as the cost is

reduced. (Steen, 2006)

The filling process depends on several phases and these include evacuation, flushing with gas,

pressurizing with gas, filling with one speed or two speeds, fill level correction and settling.

(eHow.com, 2010)

5.5.1 Modern Carbonation Systems The most important considerations for effective filling of carbonated beverages include

maintaining the content of carbon dioxide, controlling the beverage temperature during filling

and also preventing the oxygen pick up. The carbon dioxide is injected in the enclosed tank and

equilibrium between the gases and the liquid is maintained. The content of carbon dioxide

required in the tank depends on the pressure and the temperature of the beverage. The higher

the carbon dioxide content required the higher is the saturation pressure and also the

temperature will be higher. The carbon dioxide content of the beverage has a major influence

on the performance as well as the cost efficiency of the filling process.

5.5.2 Counter Pressure Fillers Carbon dioxide is absorbed under pressure and remains in solution while kept under pressure.

The pressure required in the process depends on the content of carbon dioxide in the beverage

and also the temperature. During filling process he filler bowl must be kept under the

appropriate pressure. The beverage has to be handled correctly in order to prevent the carbon

dioxide from coming out of solution due to agitation.

18

5.5.3 Glass Bottle Filling Some requirements are essential for the filing of glass bottles and these are as listed:

• Bottle handling to the filler in feed

• Bottle handling around the filler

• Lifting the bottle to the filling valve

• Air removal from the bottle prior to filling

Bottle handling to the filler in feed must be carefully controlled to avoid bottle to bottle

contact. Bottle handling around the filler must be kept under complete control and this ensures

stability.

5.5.3.1 Bottle Burst Protection

When carbonated drinks are filled in glass bottles there is a risk of bottles bursting in the filling

machine under pressure. This breakage usually occurs if the bottle has some weak point or is

damaged in some way. It is essential to protect other bottles when a burst occurs on the filling

machine so the risk of a consumer finding a piece of glass in the bottle is minimized. The

fittings are fitted with stainless steel to prevent bursting.

The most likely place for a bottle to burst is the place where the pressure is applied. The steel

are arranged here to protect the bottle.

5.5.4 PET Bottles The PET bottle was introduced in the beverage industry more than thirty years ago. This got

many advantages with it as a flexible lightweight consumer could now be used and these

bottles could easily be conveyed. They can easily store the gases and are much better than the

glass bottles.

5.6 Can Filling The introduction of beverages filled in cans for the first time was introduced in 1994. The filling

of beverages in cans became very accurate. They store gases much better than the

conventional bottles and save much more time and therefore gained popularity. The beverage

is handled more smoothly in the cans.

19

6 Equipment and Machinery

With the advancement of technology in mechanical and electronics engineering, the beverage

manufacture industry has most benefitted. The production equipment which largely used to

depend on human resource became independent and the role of workers became mere

observation. Due to the increase in demand of the product and its requirement throughout the

year, high technology fast lines are installed. Most of the equipment is imported from Germany.

The new equipment is automatically blows PET bottles, Fills it with Drink, Fills Carbon dioxide,

Caps the Bottles and pack it in crates.

Local manufacturing is hardly found. However Riaz Bottlers (Pvt.) Limited were in an installation

phase of a local line.

TABLE 3 PRODUCTION LINES AT COCA-COLA BEVERAGES PAKISTAN LIMITED (LAHORE)

Installation Product Quantity

(Cases per day)

Product Type Product Particulars

2000 24,000 RGB Regular Glass Bottles

2002 12,000 RGB --Do--

2003 12,000 RGB --Do--

2005 48,000 PET 0.5 - 1.5 liters

2009-10 144,000 PET 1.5 – 2.25 liters

2010 44,000 PET 0.5 liters

2011 60,000

Procurement Phase 2011 144,000

TABLE 4 PRODUCTION LINES AT RIAZ BOTTLER’S (PRIVATE) LIMITED

Product Quantity

(crates per hour)

Product Type

22000 PET

6000 PET

45000 RGB

20

7 Environmental Issues

The environment has always been ignored by most of the industries over many decades but

because of the serious consequences it made now it is taken as a serious issue and now annual

reports are prepared on every company’s environmental risks.

The environmental risks include the following : energy use, emission of greenhouse gases,

water use and waste water generation, organic residues and packaging residues.

Most of the manufacturers in the beverage industry donot produce their raw materials, so they

donot contribute to the protection of the natural resources. Basically the safety and the quality

of the manufactured beverages greatly depend on the quality of various natural resources, so

the preservation of environment is very important to the industry. This preservation can be

defined in terms of the returned water to the environment, that can be via municipal treatment

plants. Another important issue is of the solid wastes, according to an estimation 1kg of

produced beverages generates residues between 5kg to 50 kg. Organic residues are a

significant part of the solid organic residues in the beverage industry.

The other major environmental issue is the emission of green house gases(GHGs). They

basically come from the combustion operation of the plant i.e the fossil fuel combustion which

releases gases like (CO2, CH4 and N2O). Other gaseous emissions comes from the processes

themselves which contains particulate matter, volatile organic compounds, solvents, ammonia

and halogens. The production of these green house gases directly depend on the consumption

of the energy in the respective plant i.e both are directly related to each other. A GHG emission

intensity indicator is used to find out the total amount of GHGs emitted per unit of production.

By the use of these indicators we can see that by using electrical power production the GHGs

emissions can be reduced.

Water plays a very important role in the manufacturing and processing of the beverages. The

beverage industry could not function if it didn’t had water for processes like cooling,

condensation, steam production and the disposal of certain wastes.

Some groundwater problems can arise because most of the beverage industries use

groundwater as a source of water they need for the production of their drinks. For example

several years ago it was because of a bottling plant that the surroundings did not had any safe

water supply for drinking purpose.

The groundwater in any case has to be treated by the industry before its usage and this is done

by several other processing units.

Groundwater is not the only problem, some beverage industries offload their waste sludge as a

free fertilizer which is contaminated with high levels of lead, chromium and cadmium. Other

solid wastes includes the organic waste of the industries which are actually the residual

materials and are of no use to the industry. An organic residue intensity indicator estimates the

amount of unsold organic matter per physical unit of manufactured product. This provides an

21

indication of the effectiveness of the process in terms of minimizing the amount of residues

generated. Recycling, if possible, can also produce a differential change in the quantities of

these solid wastes.

Another type of waste are the packaging wastes which are basically produced by their

consumption. Basically packaging wastes include glass, metal, plastic, paper, cardboard, and to

a lesser extent textiles and wood, these are basically the packaging materials themselves. The

packaging wastes are being reduced by using plastics instead of metal and glass and as we

know that plastics can be recycled and are lighter in weight, so they are of great use.

The centre for science and environment (CSE) says that it tested 57 carbonated beverages

made by Coca-Cola and Pepsi at 24 bottling plants and found a ‘cocktail of between three to

five different pesticides in all samples.’

Generally the research founds that beverage industries affects the water suppliance, but the

other environmental issues such as greenhouse gas emissions and the wastes like the chemical

additives and other organic residues, all are discussed above.

Beverage industries are taking comprehensive steps to protect the environment while giving its

consumers a convenient, high quality product.

22

8 Health and Safety

As concerns over food safety and transparency continue to grow in the minds of consumers,

you are required to improve the processes you have in place that monitor quality and track

material through the facility. At each critical control point of the production process, systems

are being installed to monitor operations in order to verify that operations have been properly

executed. Systems are being implemented to track all raw and in-process material through the

entire facility to meet regulations and provide information if a product recall is required.

You may be looking at the vulnerability of the networks, automation and information systems

and implementing changes to protect your systems from intruders.

8.1 The Food Safety Management System (FSMS)

8.1.1 Policy The starting point for this standard is to have a food safety policy. It must be relevant to the

company’s position in the food chain and meet the requirements of both customers and

regulatory bodies. Having decided on policy, it must then be supported by measurable

objectives.

In addition to the food safety policy, a Food Safety Team Leader must be appointed who,

regardless of other duties, must head up a Food Safety Team. This team must have multi-

disciplinary knowledge of the products, processes, equipment and food safety hazards.

In effect, this is the Hazard Analysis and Critical Control Point (HACCP) team but now with wider

responsibilities.

8.1.2 HACCP The need for an assessment of the hazards associated with each material used is required.

There are seven principles and twelve steps required to complete and implement a HACCP

approach.

Principle 1 – Conduct a hazard analysis (identifying potential biological, chemical or physical

contamination that can affect health):

• A team of experts is assembled to draw up a full product specification, including its

preservative regime, packaging and distribution method.

• Mode(s) of use for the product and potential misuses or uses by particularly vulnerable

groups of the population must be identified.

• A flow diagram of all the steps in the production process must be constructed.

23

• And an on-site verification of the flow diagram carried out

• All the potential hazards that may reasonably be expected to occur at each step of the

process up to the point of consumption must be listed.

Principle 2 – Determine the critical control points (CCPs):

• A decision tree should be used to identify whether any particular point is a CCP or not.

• If there is no control measure in place at a CCP (or elsewhere to the same effect), then

the process should be changed to implement one.

Principle 3 – Determine the critical limits:

• Limits should be set for each critical control point, sometimes several limits at one point.

Principle 4 – Establish a system to monitor control of the CCPs:

• It is necessary not only to monitor but also to control, that is, to take corrective action if

trends show that the limits may soon be exceeded, or alternatively, the responsible

person notified

Principle 5 – Establish the corrective action to be taken when monitoring indicates that a

particular CCP is not under control:

• Once a CCP limit has been exceeded, the corrective action is two-fold (as identified in

ISO 9001).

• First, to identify the action to bring the process back into control. There is often a

dilemma – does production continue to make a defective product because it is easier to

adjust the process whilst it is running or, is the process stopped and a wasteful start-up

procedure carried out after fixing the fault?

• Second, what to do with the product manufactured during the ‘out of control’ period.

Such a product will need to be isolated, but how much and what can be done with it?

Principle 6 – Establish procedures to verify that the HACCP system is working effectively:

• Auditing the controls is an obvious verification activity but random tests or spot-checks

can also reveal deficiencies

24

Principle 7 – Establish documentation concerning the procedures needed and keep appropriate

records:

• The tests carried out to demonstrate that CCPs are being monitored and are in control

are the most obvious records.

• Procedures and training records for the persons carrying out the CCP monitoring need

to be retained.

• In addition, those who carried out the HACCP study, their findings and decision-making

process need to be documented

25

Bibliography

Ahmed Naeem Reflection [Report]. - Karachi : Daily Jang, 2003.

Business Wire Pakistan Food & Drink Report Q4 2006 [Online] // Business Wire. - Business

Wire, June 29, 2007. - March 8, 2010. -

http://www.businesswire.com/portal/site/home/permalink/?ndmViewId=news_view&newsId=

20070629005236&newsLang=en.

Coca-Cola Coca-Cola United States [Online] // Coca-Cola. - The Coca-Cola Company, 2010. -

March 8, 2010. - http://www.coca-cola.com.

Dolcera Premium Coffee Market Segmentation [Online] // Dolcera. - August 6, 2009. - March 8,

2010. -

http://www.dolcera.com/wiki/index.php?title=Premium_Coffee_Consumers_Market_Segment

ation.

eHow.com How are Drinks Carbonated? [Online] // eHow.com. - eHow, Inc, 2010. -

http://www.ehow.com/how-does_5137671_drinks-carbonated.html.

Euromonitor International Soft Drinks in Pakistan [Online] // Euromonitor International. -

Euromonitor International, May 2009. - March 9, 2010. -

http://www.euromonitor.com/Soft_Drinks_in_Pakistan.

First Capital Equities Ltd Company Report [Online] // Daily Times - Leading News Resource of

Pakistan. - Unilever, February 07, 2010. - March 9, 2010. -

http://www.dailytimes.com.pk/default.asp?page=2010%5C02%5C07%5Cstory_7-2-

2010_pg15_3.

Jamal's Jamal's Yellow Pages [Online] // Yellow Pages. - U.S. Publishers (Pvt) Limited, 2008. -

March 8, 2010. - http://www.jamals.com/.

Pepsi Pepsi [Online] // Pepsi. - Pepsi Co. Inc., 2010. - March 8, 2010. - http://www.pepsi.com/.

Soft Drink [Online] // madehow.com. - Advameg, Inc. - http://www.madehow.com/Volume-

2/Soft-Drink.html#ixzz0hWPvcnQC.

Steen David P. Carbonated Soft Drinks Formulation and Manufacture [Book] / ed. Ashurst Philip

R.. - Chennai : Blackwell Publishing, 2006. - pp. 1-15.

Wikipedia® Drink [Online] // Wikipedia. - Wikimedia Foundation, Inc., February 27, 2010. -

March 8, 2010. - http://en.wikipedia.org/wiki/Drink.

a

Appendix A

TABLE 5 LIST OF PAKISTANIBEVERAGE BRANDS (JAMAL'S, 2008)

Company Product Range Location and Contact

1) Ahmed Foods (Pvt.)

Limited

Syrups and

Squashes

Ahmed House, D-112, Ahmed

Avenue, S.I.T.E, Karachi

(92 21) 32563524, 32563520,

[email protected]

2) Amrat Cola

Carbonated Drinks House # 9, Main Double Road,

I-8/3, Islamabad

(92 51) 4449528, 4448735

3) Al-Makka Cola

Carbonated Drinks C-34, Sector 13-A, K.D.A.

Scheme 33, Karachi

(92 21) 34652567, 34656938

[email protected]

4) Coca-Cola Beverages

Pakistan Limited

Carbonated Drinks

(Coca-Cola, Sprite,

Fanta, Sprite 3G)

D-51, Estate Avenue, S.I.T.E.,

P.O. Box 75700 Karachi

(92 21) 32576354, 32576351

5) Continental Beverages

(Pvt.) Limited

Carbonated Drinks

(RC Cola)

D-210, S.I.T.E., Estate Avenue

Karachi

(92 21) 32577001, 32577000

[email protected]

6) Frooto Industries

(Pvt.) Limited

Juices

C-1/A, S.I.T.E., Karachi

(92 21) 32582711, 32561393

[email protected]

7) Haleeb Foods Limited

Milk 135, Ferozepur Road,

Lahore

(92 42) 37573128, 37573125

8) Hamdard Laboratories

(Waqf) Pakistan

Syrups Al-Majeed, Hamdard Centre,

Nazimabad-3, Karachi

(92 21) 36616001, 36620945

[email protected]

9) International

Beverages (Pvt.) Limited

Carbonated Drinks 270, Sector 1-9, Industrial Area

Islamabad

(92 51) 4411535, 4411533

b

10) Jannat Cola

Carbonated Drinks 51, Century Tower, Kalma

Chowk, Main Boulevard,

Gulberg-III, Lahore

(92 42) 35846127, 35844135

11) Maaza Pakistan

(Pvt.) Limited

Juices Plot #19-20,Sector-15,Korangi

Industrial Area, Karachi

(92 21) 35070849, 35071531

12) Mehran Bottlers

(Pvt.) Ltd.

Carbonated Drinks

(Pakola, Apple Sidra,

Bubble Up)

C/5-A,S.I.T.E.

Karachi

(92 21) 32570615, 32570614

[email protected]

13) Mitchell’s Fruit

Farms Limited

Juices, Syrups Mehran VIP-II Ground Floor,

Plot 18/3, Dr. Dawood Pota

Road, Karachi

(92 21) 35219675, 35212112

[email protected]

14) Murree Brewery

Company Limited

Lemonades(Original,

Diet & Apple)

Energy Drinks

3-National Park Road, P.O. Box

No. 13, Rawalpindi

(92 51) 5567041, 5567047

[email protected]

15) Naurus (Pvt.)

Limited

Syrups, Juices and

Squashes

C-1/B, Naurus Chowrangi,

Manghopir Road, S.I.T.E,

Karachi

(92 21) 32577853, 32577851

[email protected]

16) Nestle Pakistan

Limited

Juices Plot #15/1, Sector-15, Korangi

Industrial Area, Opp. Aslam

Masjid, Karachi

(92 21) 35021288, 35073940

[email protected]

17) Pakistan Beverage

(Pvt.) Ltd.

Carbonated Drinks

(Pepsi, Dew, 7up,

Miranda)

Juices (Slice)

D-113, S.I.T.E., Manghopir

Road, Karachi

(92 21) 32569801.32569805

[email protected]

18) Pepsi-Cola

International (Pvt.)

Limited

Carbonated Drinks

(Pepsi, Dew, 7up,

Miranda)

Juices (Slice)

43-T, Gulberg-III, Lahore

(92 42) 35872167, 35872162

[email protected]

c

19) Popular Juice

Industries Limited

Juices 311-313, Chapal Plaza, Hasrat

Mohani Road, Karachi

(92 21) 32420223, 32420222

[email protected]

20) Pure Foods

Company (Pvt.)

Limited

Syrups Missan Kollar, Old Pindidas Rd.,

17-km Sheikhupura Road,

Lahore

(92 42) 37971121

[email protected]

21) Qarshi industries

(Pvt.) Limited

Syrups Plot #56, 56/1-4, Phase-III,

Industrial Estate, Hattar,

Haripur

(92 995) 617173, 617373

[email protected]

22) Shandy Cola

Pakistan

Carbonated Drinks Plot # 129/7, Quaid-I-Azam

Industrial Area, Kit Lakhpat,

TownShip, Lahore

(92 42) 35213491, 35213495

[email protected]

23) Shezan

International Limited

Juices, Syrups L-9/22, F.B. Industrial Area,

Karachi

(92 21) 36344722, 36344723

24) Tops Foods &

Beverages Limited

Fruit juices 3-National Park Road,

Rawalpindi

(92 51) 5567047, 5567041

[email protected]

25) 7Up Bottler (Pvt.)

Limited

Carbonated Drinks 35-Industrial Area, Gulberg-III

Lahore

(92 42) 35761244, 34761243

d

Appendix B

VISIT TO COCA-COLA BEVERAGES PAKISTAN LIMITED (LAHORE)

On Friday 12th March, our group visited the Coca Cola Beverages Limited Located 23

Kilometers, Raiwand Road, Lahore. We were received by Mr. Muhammad Asif, the Line

Manager at unit. He entertained us and gave us valuable information regarding the processes

occurring in the factory. We were told about the Coca Cola Beverage Industry. “The bottling

unit was turned into an automatic plant in 2005”, shared Mr. Asif.

Information was provided on the setup structure of the industry. We were told about the

production planning, procurement, stores supply, production and about the warehouse of the

goods. The operation of the industry was told as well and after this our guide told us about the

Key Process Indicators. These included the Water treatment, syrup manufacture and the waste

water treatment.

After giving us a brief knowledge of the processes we were taken to see the manufacture of

Coke. We were taken in different rooms. Here we saw how the PET bottles were made, how

fast they were being filled, how they were being purified, how coke was being filled in them.

After seeing the production of fresh coke we were shown the packing and the storage of the

bottles. How they were dispatched and stored to be sent on so that it can be sent to the

consumers.

The visit was a highly entertaining one which taught us a great deal and gave us valuable

information regarding the production of coke and helped a great deal in our project on the

beverage industry.

FIGURE 8 GROUP PHOTO WITH OUR MENTOR FROM CCBPL

e

Appendix C

VISIT TO RIAZ BOTTLES PRIVATE LIMITED (LAHORE)

On Saturday 13th

March, our group visited the Riaz Bottlers Limited situated in Gulberg, Lahore.

We were received by Mr. Iftikhar Ahmed, (Technical and Opertational Manager- PET), took us

to the tour of the unit and provided us with the valuable information regarding the processes.

We were lead to Water Treatment setup, Sugar storage, syrup manufacture, Concentrate

Storage, and Bottling area, followed by the Blowing Section for PET bottles.

Passing through the water treatment area, we were lead to Control Room of the section. P&ID

chart were shown followed by individual exhibition of process equipment.This was followed by

sugar storage and syrup room. Heat Exchanger equipment was used for cooling the

temperature of the concentrate both in syrup manufacture and syrup storage. Then we were

taken to mixing section, where all the raw materials are mixed in large mixers and are stored in

silos.Then we were directed to bottling area where we first saw the preparation of PET bottles.

Blowing machines were used for preparing the bottles from imported pre-form. Process was

catered at high temperature and pressure to obtain the required shape of the bottle.Further,

we saw the process of bottling in which prepared drinks were poured into the bottles. Three

types of bottling were going on depending on the speed of the movement of bottles.We then

visited the capping and crowning of different types of bottles, its labeling and finally the packing

in cartons and storage in the store houses before delivery.

The visit was a highly entertaining one which taught us a great deal and gave us valuable

information regarding the production of carbonated beverage and helped a great deal in our

project on the beverage industry.

FIGURE 9 GROUP PHOTO WITH OUR MENTORS FROM RBL, LAHORE

beverages industry

Documents