Professional Documents
Culture Documents
Beverage Industry
(Carbonated Drinks)
Spring ‘10
Instructor
Dr. Noaman ul Haq
Summary
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.
Acknowledgements
We are thankful to Almighty Allah for His unlimited blessings and bounties;
for keeping us sane, sound and successful,
Our Instructor Dr. Noaman ul Haq, for all his guidance and appreciation,
and all our teachers, friends and colleagues for their help in completion of
this report.
iii
Table of Contents
SUMMARY ....................................................................................................................................................... I
ACKNOWLEDGEMENTS .................................................................................................................................... II
1 INTRODUCTION ....................................................................................................................................... 1
BIBLIOGRAPHY .............................................................................................................................................. 25
APPENDIX A .................................................................................................................................................... A
APPENDIX B .................................................................................................................................................... D
APPENDIX C .................................................................................................................................................... E
v
List of Figures
1 Introduction
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.
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)
2 Beverage Industry
2.1 Consumption Patterns of Beverages
The average annual beverage consumption of US population as per according to the 2008
Beverages Market Research Handbook is as under:
TABLE 2 ANNUAL BEVERAGE CONSUMPTION
CONS IN USA (2008) (DOLCERA, 2009)
Distilled
Tea, 4.11 Spirits, 0.73
Fruit Carbonated
Beverages, 6. Wine , 1.14 Soft
97 Drinks, 26.22
Milk, 10.87
Coffee, 11.24
Beer, 11.34
Tap Water, 13
Bottled
Water, 14.36
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)
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.
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.
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.
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)
A survey was carried out by the team to observe the trends for preferences of beverages.
Following results were observed:
Beverage Priorities
Milk
22%
Fruit Juice
Drink 60%
18%
Why turnover of carbonated water industry is more even though most people prefer fruit
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
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
requires a carbonated drink to aid in digestion.
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.
80%
70%
60%
50%
Fruit Juice
40% Drink
Milk
30%
20%
10%
0%
Female below 25 Male below 25 Female above 25 Male above 25
• 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
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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.
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5 Industrial Processing of Beverages
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.
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
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constituents and gets contaminated. It is therefore required to first clean the water before
using it as a solvent. Hence water
water treatment carries great significance in a beverage industry.
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.
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
beverage industry.
Ultra Violet
Carbon Filtration Chlorination
Filtration
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.
5.2.4 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.
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.
5.2.13 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.
Activated Carbon
Sugar Warehouse Buffer Tank
Tank
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.
The recovery
ecovery 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 eefficiency by increasing
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 ststream
ream to react with the acid gases (SO2 or NOx).
The reactions results into formation of solid salts which are removed in the particulate control
devices.
The most important consideration for effective filling of carbonated beverages are to maintain
the content,
nt, 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 required
requir beverage
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:
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)
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.
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.
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.
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.
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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.
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.
• 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.
• Limits should be set for each critical control point, sometimes several limits at one point.
• 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
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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.
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ation.
eHow.com How are Drinks Carbonated? [Online] // eHow.com. - eHow, Inc, 2010. -
http://www.ehow.com/how-does_5137671_drinks-carbonated.html.
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http://www.dailytimes.com.pk/default.asp?page=2010%5C02%5C07%5Cstory_7-2-
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March 8, 2010. - http://www.jamals.com/.
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a
Appendix A
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.
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.