TO STUDY THE WINE PROCESSING TECHNOLOGY & PLANT DESIGN OF WINERY

Project Report Submitted to the N.D. Wines Pvt. Ltd., Nashik In partial fulfillment of the requirements for the degree of Bachelor of Technology (FOOD TECHNOLOGY)

By Vinay Kumar & Amit Kumar JAIPUR NATIONAL UNIVERSITY July 2011

ACKNOWLEDGEMENT

Completion of any task is not at all a single person effort. It demands hard work, motivation, experience of many people. This project is also a team work effort and to be a part of this quality improvement team is a proud privilege. It gives me immense pleasure to acknowledge and remember all those who set my way for successful completion of this project.

I am grateful to Mr.Vijay Kulkarni(General manager, N.D Wines Pvt. Ltd., Nasik), for allowing me to do my industrial training/project.

I sincerely acknowledge Mr.Achyut Niphade (Production manager) for providing their valuable time and helping me

I take this opportunity to express my deep sense of gratitude to Mr. Sandeep Bakshi , CEO & Director of Jaipur National University, for pursuing such a great course of Food Technology in the institute and providing us such a wonderful environment for studies and supporting us to have a good career in Food Technology.

I am also obliged to Lecturers Mr. Rahul Agarwal, Mr. Rahul Saxena, Ms. Monica Premi for their guidance and suggestions. Place : Nasik Dated : July 2011 Vinay Kumar

TABLE OF CONTENT
S. No 1 2 3 3 Content No. 1.0 2.0 3.0 4.0 Topic Introduction Company Profile Wine Processing Technology Quality Standards of wine Plant layout & Design

5.0

Plant cost evaluation

6.0

Capital Investment

7.0

Total Production cost

4.0

Results and Discussion

5.0

Glossary and Acronyms

6.0

Literature Cited / References

1.INTRODUCTION 1.1 COMPANY PROFILE:

N.D. GRAPES Mr. Ashok Gaikwad and his friends together established N. D. Grapes Pvt. Ltd. in the year 1993, N. D. Grapes started exporting table grapes to various countries all over the world. After regular and stringent checks the renowned supermarkets in the U. K. like Tesco and J. Sainsbury have conferred the certificate of merit to N.D. Grapes for adopting world class standard for preserving the fruit and maintaining and storage plants. N. D. Grapes is the regular and sole supplier to J. Sainsbury, Tesco and Marks & Spencers. Within a short period N. D. Grapes became the most favored brand in countries like Hong Kong, Singapore, Malaysia, Africa, Europe etc. N. D. Grapes is the first company to get the distinction of single largest exporter of India.

N .D. WINES PVT. LTD. After enjoying huge success N. D. Grapes have now ventured into ancient and exquisite art of wine making under the banner of N.D. Wines Pvt. Ltd. The beautifully landscaped winery is located on the lake side and surrounded by lush green vineyard. At the winery the time tested art of wine making has gained greater height under the expert eye of the famous French wine master Mr. Jean Manual Jacquinot. The state of the art winery is well equipped with all imported machinery made by the renowned French companies. With growing demand from the customers, we have enhanced our crushing capacity from 200 tonnes to 1400 tonnes. N. D. Wines is geared up to fulfill the rising demand of todays international wine market. INFRASTRUCTURE At N.D. Wines we believe Good taste is an important ingredient so utmost care is taken to produce the best quality wines. Our winery is made as per French standard with all imported machinery. The winery has a tank capacity of 9,91,000 liters for storage of wines. N.D. Wines adopts world class manufacturing and storage techniques for making and preserving wines.

CORE COMPETENCY N.D. Grapes is the single highest exporter of home grown grapes for past several years. The 700 acres highly cultivable and spread out across the foothills of the Sahyadri range has been the mainstay of our vine yards. N. D. Wines is the first winery in India to grow the world famous Cabernet Sauvignon-reserve and Sauvignon Blanc- reserve used in making reserve wines on the virgin soil. We have also mastered the art of growing Shiraz, Cabernet Sauvignon, Chenin Blanc, Sauvignon Blanc the are specially used in making different variety of wines.

Grapes in Nasik In India, the land of Nasik is a heaven for growing internationally acclaimed table and wine variety grapes. Nestling at the feet of the Sahyadri Hills, Nasik is endowed with suitable soil. Its pleasant, dust free and non corrosive climate, matching the topography of the south of France, making it conducive for the growth of the wine fruit.

ACHIVEMENT In short span of time N. D. Wines is very well known brand in the market and widely accepted by the customers as the premium wine maker. We have strong holds in major states across India like Maharashtra, Goa, Diu, Daman, Silvassa, Rajasthan, U.P., Chandigarh, Karnataka, M.P., Delhi etc. We are very proud to announce that N.D. Wines is one of the wines served in prestigious and luxurious trains like The Deccan Odyssey promoted by Maharashtra Government and Palace on Wheels promoted by Rajasthan Government. N. D. has also won the international level Excellence Award for Entrepreneurship from J.M.C.C.I. presented by his Excellency S. M. Krishna Governor of Maharashtra in Jan. 2005.

MISSION In continuation of our legacy to produce globally approved quality grapes, now our mission is to offer world class Wines to all customers.

1.2 WORK / DEPARTMENT

1.2.1 HUMAN RESOURCE AND ADMINISTRATION The main function of this department is to record all the activities of the plant and complete administration of the plant is carried out under this department. It is the head office of the plant and this department controls all the activities regarding human resource development. It also maintains aspects like salary, training etc. This department keeps all the records and finance of the unit. It also looks in giving pay to the employees. 1.2.2 PURCHASE SECTION This is section where all types of needs which helps to the production or help in the normal functioning of the company like raw materials, machines, packing material, etc. Besides this all type of assets(e.g. Stationary, P.C etc) are also controlled by this departments. 1.2.3 PRODUCTION DEPARTMENT Here, there are two different production area Red Wine and White Wine production. 1.2.4 MAINTENANCE DEPARTMENT During production different types of troubles are faced by the production department these related to the machinery and process for these troubles a department called maintenance department, which helps production department. This section looks after and repairs all of the machineries time to time and when required. The objective of this department is to oversee maintenance of different commodities (electricity, machinery, etc.). 1.2.5 STORE & LOGISTICS DEPARTMENT These both are different but they work together, store department are related to the finished goods as well as raw materials also. It maintains FIFO and appropriate condition for the storage of materials, where logistics dispatch the finished goods to the distributor or according to the procedure they also maintain FIFO for the dispatch.

1.2.6 EXCISE DEPARTMENT:

1.3 WINES VARITIES:

1.3.1 SYRAH
This wine is made from Syrah, grown on the virgin soil of the Sahyadri hills located in Nasik, the climate here is very similar to that of the South of France. Before pressing the grapes are specifically selected and picked at perfect maturity level. N. D. Syrah has the color of the royal insignia, deep purple. The overpowering nose is a reminder of the warm climate of the area, the strong aroma of bell peppers blends well with soft aroma of cherries and blackcurrants, N.D. Syrah feels velvety to taste with a distinct peppery flavor that lingers in the mouth. N.D. Syrah goes well with Indian cuisine and is ideal with food cooked in the Tandoor as well as with spiced vegetables. Best served at : 18C.

1.3.2 Cabernet Syrah

This wine is made from Cabernet Syrah, grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine has got a rich deep red color and is perfectly balanced. All the characteristics of the nice fruity aromas from the N.D. Syrah are present and are reinforced by the full bodied structure of the N. D. Cabernet. The Length of this wine is perfect. This wine is perfect with all the Indian Foods. Best served at : 18C

1.3.3Cabernet Sauvignon
This wine is made from Cabernet Sauvignon, grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine comes in a striking deep red color. The nose develops a lilting aroma of bell pepper, cherries and

blackcurrants. Cabernet Sauvignon tastes like the warm climate of India, melting with the tannin coming from the mature seeds and the after taste lingers in the mouth. This wine is ideally served at dinner with any Indian dish. Best served at : 18C to 20C.

1.3.4Cabernet Sauvignon Reserve

This wine is made from Cabernet Sauvignon, grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine comes in a striking deep red color. The nose develops a lilting aroma of bell pepper, cherries and blackcurrants. Cabernet Sauvignon tastes like the warm Indian climate with a touch of silk. This exotic wine can be served during and after dinner & goes well with all Indian cuisine. Best served at : 18C to 20C.

1.3.5Galaxy Red
This wine is made from Cabernet Sauvignon, grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine comes in a striking deep red color. The nose develops a lilting aroma of bell pepper, cherries and blackcurrants. Cabernet Sauvignon tastes like the warm climate of India, melting with the tannin coming from the mature seeds and the after taste lingers in the mouth. This wine is ideally served at dinner with any Indian dish. Best served at : 18C to 20C.

1.3.6 Sauvignon Blanc Reserve

This wine comes from Sauvignon Blanc grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. This wine comes

in a striking green gold color. The nose develops a pleasant aroma of pineapple, banana, guava and the typical aroma of grapefruit. Sauvignon Blanc is tangy, with a rich freshness that leaves behind a lingering citrus and lemon flavor in the mouth. This richly flavored wine is the perfect appetizer that goes well with any variety of fish, as well as steamed lobster. Best served at : 10C.

1.3.7 Chenin Blanc

This wine is made from Chenin Blanc, grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. The color of this wine is pale yellow with touches of green. The intense nose develops the pleasant aroma of pineapples, grape fruits and native guavas, besides the flowery aroma of rose. The tangy taste of the N.D. Chenin Blanc tickles the palate and leaves a lasting flavor and aroma of fruit in the mouth. This wine is a perfect appetizer and goes well with food cooked in light spices followed by fish. Best served at : 10C.

1.3.8 Sauvignon Blanc

This wine comes from Sauvignon Blanc grown on the virgin soil of the Sahyadri hills located in Nasik. Before pressing the grapes are specifically selected and picked at perfect maturity level. N.D. Sauvignon Blanc comes in enchanting pale gold green color. The nose develops exotic aromas of blackcurrant leaves touched with a sweet whiff of pineapples, grapefruits, bananas and guavas with a noticeable aroma of grapefruit. N.D. Sauvignon Blanc carries a lemony flavor which leaves a tingling freshness in the mouth. This wine is an ideal appetizer that can be served with cashew nuts and almonds. It is suitable for all types of fish and steamed jumbo prawns and goes well with delicately spiced Indian cuisines. Best served at : 10C.

2.0 Wine Processing Technology:

2.0.1 Introduction:
Wine is an alcoholic beverage, made of fermented fruit juice, usually from grapes. The natural chemical balance of grapes lets them ferment without the addition of sugars, acids, enzymes, or

other nutrients. Grape wine is produced by fermenting crushed grapes using various types of yeast. Yeast consumes the sugars in the grapes and converts them into alcohol. Different varieties of grapes and strains of yeasts produce different types of wine. Wines made from other fruits, such as apples and berries, are normally named after the fruit from which they are produced (for example,apple wine or elderberry wine) and are generically called fruit wine or country wine

2.0.2 History
Archaeological evidence suggests that the earliest known production of wine, made by fermenting grapes, took place as early as 8,000 years ago in Georgia and 6,100 years ago inArmenia. These locations are all within the natural area of the European grapevine Vitis vinifera.

Pressing wine after the harvest;Tacuinum Sanitatis, 14th century Through an extensive gene-mapping project in 2006, Dr. McGovern and his colleagues analyzed the heritage of more than 110 modern grape cultivars, and narrowed their origin to a region in Georgia, where also wine residues were discovered on the inner surfaces of 8,000-year-old ceramic storage jars in Shulavari, Georgia. Other notable areas of wine production have been discovered in Greece and date back to 4500 BC. The same sites also contain the world's earliest evidence of crushed grapes. On January 11,

2011 in one of Armenia'sVayots Dzor province cave was found a wine making press dating to approximately 6,000 years ago.Literary references to wine are abundant in Homer (9th century BC, but possibly composed even earlier), Alkman (7th century BC), and others. In Ancient Egypt, six of 36 wineamphoras were found in the tomb of King Tutankhamun bearing the name "Kha'y", a royal chief vintner. Five of these amphoras were designated as from the King's personal estate with the sixth listed as from the estate of the royal house of Aten. Traces of wine have also been found incentral Asian Xinjiang, dating from the second and first millennia BC. Viticulture in India has a long history dating back to the time of the Indus Valley

civilization when grapevines were believed to have been introduced from Persia sometime in the 5000 BC The first known mentioning of grape-based wines was in the late 4th century BC writings ofChanakya who was the chief minister of Emperor Chandragupta Maurya. In his writings, Chanakya condemns the use of alcohol while chronicling the emperor and his court's frequent indulgence of a style of grape wine known as Madhu A 2003 report by archaeologists indicates a possibility that grapes were mixed with rice to produce mixed fermented beverages in China in the early years of the seventh millennium BC. Pottery jars from the Neolithic site of Jiahu, Henan contained traces of tartaric acid and other organic compounds commonly found in wine. However, other fruits indigenous to the region, such as hawthorn, cannot be ruled out.If these beverages, which seem to be the precursors ofrice wine, included grapes rather than other fruits, these grapes were of any of the several dozen indigenous wild species of grape in China, rather than from Vitis vinifera, which were introduced into China some 6000 years later. One of the lasting legacies of the ancient Roman Empire was the viticulture foundation the Romans laid in the lands that today are world renowned wine regions. Areas with Roman garrison towns, like Bordeaux, Trier, and Colchester, the Romans planted vineyards to supply local needs and limit the cost of long distance trading. In medieval Europe, the Roman Catholic Church staunchly supported wine, since they required it for the Mass. Monks in France made wine for years, aging it in caves. An old English recipe that survived in various forms until the 19th century calls for refining white wine from bastardbad or tainted bastardo wine.

2.0.3 Grapes Varities

N.D wines has produced red and white type of wines from SYRAH, CABERNET SAUVIGNON, CHENNIC BLANC, SAVIGNON BLANC. These Varieties of grapes are especially selected and picked when at perfect maturity level in own grown vineyards.

2.0.4 Processing Method

Flow Chart: For White wine making

Harvesting of grapes

Pressing

Chilling & Settling

Racking

Fermentation

Racking

Clarification & Stablization

Storage

Blending(optional)

Filteration

Bottling

Corking,Labelling & Packaging

Flow Chart: For Red wine making

Harvesting of grapes

Destemming & Crushing

Chilling

Fermentation with skin

Pressing

Malo-Lactic fermentation

Racking

Clarification & Stablization

Storage

Blending (optional)

Filteration & Bottling

Corking,Labelling & Packaging

2.0.5 Process of Wine making:

The process of wine making involves following steps: 1) Crushing/pressing After Harvesting the grapes are bought to the winery where special machines are used to destem the grapes and crush it to remove the stems which contain astringent tannins and to break the skins of the grapes without crushing the seeds. Like the stems, the seeds contain harsh, unwanted tannins.

Press machine The grapes which are used for white wine are dumped to pneumatic press for juice extraction. After removal of juice the left over materials such as stem, skin and seeds are removed. During the press cycle every attempt is made to prevent unnecessary bruising to the stem , skin and seeds. This is done to avoid tannin or any undesirable extract getting into the juice. The grapes are used for making red wine are first destemmed and then crushed. Destemming is the process of separating stems from the grapes. Depending on the wine making procedure, this process may be undertaken before crushing with the purpose of lowering the development of tannin and vegetal flavors in the resulting wine. After destemming the grape berries are immediately crushed by passing it through the two rubber rollers rotating in opposite direction. Crushing is the process that breaks apart the grape

berries and allows the juice to pass through the fermentation tank along with the skin and seeds. Crushing usually starts immediately after destemming using an equipment called crusher-destemmer.

Destemmer

Now along with the juice there is addition of SO2 . The main purpose of addition of SO2 is to suppress the growth of bacteria, most of which are sensitive to it. It acts like a preservative and antioxidant. This SO 2 combines with the anthocyanin pigment and make them more soluble and added in the form of KMS(potassium metabisulphite). As soon as the juice sugar level, ph and titrable acidity is checked.

2) Chilling:
The juice which is extracted is now allowed to get chilled. Thus due to chilling effect the lees particles such as dust, fibres, cellulose and any unwanted particles to get settle down. The chilling continues for 24 hours in case of white wine and 48-72 hours in case of red wine.

3) Fermentation:
Wine fermentation takes place when yeast ( s.cerevisiae) consumes the natural sugar present in grape juice and converts it into alcohol and carbon dioxide under anaerobic condition. The process of fermentation requires careful control for the production of high quality wines. Requirements include

suppression of growth of undesirable microorganisms, presence of adequate numbers of desirable yeast, proper nutrition for yeast growth, temperature control for excessive heat, prevention of oxidation and proper management of the cap of skins floating in the red must. Although species of Saccharomyces are generally considered more desirable for efficient fermentation. Saccharomyces is preferred because of its efficiency in converting sugar to alcohol and because it is less sensitive to the inhibiting effect of alcohol. Under favorable conditions, strain of Saccharomyces cerevisae have produced up to 18%v/v of alcohol, although 15 to 16% is usual limit. Optimum temperature for growth of common wine yeast is 25oC. Temperature control during alcoholic fermentation is necessary to :

Facilitate yeast growth Extract flavors and colors from the skins Permit accumulation of desirable by products Prevent under rise in temperature which kills the yeast cells.

In case of white wine the juice usually is fermented at about 11-18oC, while in case of red wine it is fermented at about 18-22oC. Temperature in the lower end of fermentation gives the wine having straight forward fruit flavours and prevents undue loss of alcohol, But higher temperature leads to fast and vigorous fermentation leading to complex characterized wine.

Fermentors

4) Racking:
This is one of the essential step in wine making i.e. to siphon the wine off the sediment (lees) into another clean secondary, reattach the fermentation trap, and repeat after another one or two months and again before bottling. This procedure is called racking. It is done when necessary, not just two or three times as stated above. The rule is, as long as there are fresh deposits on the bottom after a regular interval ( 30 to 60 days), even if they are just a light dusting, the wine should be racked. Only when that interval passes and there are no fresh lees and the specific gravity is 1000 or lower is the wine ready to be prepared before bottling. It is not necessary that the interval between racking be 30 days, 45 days , 60 days, but it should not be less than 3 weeks. It is perfectly okay that to leave the wine on the lees for 3 months , Beyond that and the wine enters a danger zone caused by dead yeast cells breaking down rotting, while this can cause off-flavors and odours if allowed to go on too long, the bigger danger is the formation of hydrogen-sulphide gas, which smells like rotten eggs and can be the death of wine. But if lees are stirred every week or so, neither the off flavors nor hydrogen-sulphide gas formed. Indeed the wine is actually improved by extended contact with the lees as they are stirred frequently.

During this entire period, the sulphur dioxide gas released into the wine from crushed Campden tablets or KMS is slowly dissipated through the air lock and its protective qualities are lost. It is therefore necessary to replenish this protection, and this is done at every other racking, the new sulphites are added to the receiving secondary and the wine racked into it.

Racking pump

5) Clarification and Stabilization:

The clarification and stabilization of winemaking involves removing insoluble and suspended materials that may cause a wine to become cloudy, gassy, form unwanted sediment deposit or tartaric crystals, deteriorate quicker or developed the assorted wine faults due to physical, chemical and microbiological instablility. These process may include fining, filteration, centrifugation, floatation, refrigeration, barrel maturation and racking. Most of these process will occur after the primary fermentation and before the wine is bottled. The exception is for white wine production which will usually have the must separated from some of grapes skin and particles prior to fermentation so as to avoid any unwanted maceration. The timing and exact methods used will vary by producer, depending upon desired finish product such as a completely bright and clear wine or a wine that still remains some of the flavors and color phenols. The material are removed from the must during this stage winemaking dead yeast cells, bacteria , tartartes, proteins, pectins various tannins and other phenolic compounds and pieces of grape skins, pulp, stems and gums. The process of clarification is also called as fining process. Fining agents may includes casein, gelatin, bentonite, Spanish clay etc..The stabilization process involves chilling the clarified wine in order to cause the precipitation of potassium bitartarate in the form of crystals. The process of stabilization increase the clarity and brightness of a wine.

6) Storage:
The storage of wine is important step in winemaking. The storage of wine basically means aging of wine. The main purpose of aging is to develop the aroma. This is carried in two ways: Oak barrels Stainless steel tanks containing Oak chip

N.D Wines has using the process of stainless steel tanks in addition of oak chips a/c to requirement and have a advantage of this method no penetration of oxygen is possible.

7) Filteration:
Filteration is a technique used for clarification and microbiological stabilization was introduced to wine making only 30-40 years ago. The advantage of filteration over fining is that it can clarify a young, cloudy wine faster and more efficient than fining . It clarifies by removing particles in suspension that cause cloudiness.

8) Bottling:
The first step in bottling of wine is depalletising, where the empty bottles are removed from the original pallet packaging delivered from the manufacturer, so that individual bottles may be handled. The bottles may then be rinsed with filtered water or air, and may have carbon dioxide injected into them in attempt to reduce the level of oxygen with in the bottles. Then bottle enters in filling machine which fills the wine (750 ml, 375 ml SWMA) in bottles and may also inject a small amount of CO2 inert gas on top of head space of bottle. Then bottle going to corking machine(corker) where a cork is compressed and pushed into the neck of bottle. Whilst this is happening the corker vacuum the air out from bottle to form a negative pressure head space. This removes any oxygen from the head space, which is useful as O2 can run the quality of product by oxidation. A negative pressure headspace will also counteract pressure caused by the thermal oxidation of wine, preventing the cork from being forced from the bottle. Some bottling lines incorporate a fill height detector which reject under or over-filled bottles and also a metal detector.

9) Packaging:
When packaging is ideal for presentation, which helps add value and boost sales of wines and spirits. These packages can also be customized with personal messages. Weddings, birthdays, anniversaries, luxury cruises, promotional events are some of the occasions when a memorable gift of excellent wine

can be given with eloquent wine packaging. Generally, CFB box, wooden pallets and butter paper for wrapping the wine bottles are used as packaging material.

3.0 Quality Standards of Wine:

These standards are Parameter
0

White wine standard 20-23% 3.20-3.35

Red wine standard 24-26% 3.65-3.75

Role of component Maturity level Related to activity of enzymes & taste

Brix

pH

Titrable acidity

7-9 gm/ltr

5.0-6.5 gm/ltr

Taste, sweet balance, storage life

Volatile acidity

0.05-0.06%

0.06-0.08%

Leads to off flavor, spoilage

So2

25-28 ppm

28-32 ppm

To prevent oxidation, preservation

Co2

1000-1400 ppm

400-600 ppm

It

escape

O2,

carry

aroma N2 Juice content 175 ppm 175 ppm Required for proper

growth of yeast while fermentation N2 gas content in wine 0.5-0.6 ppm 0.7-0.8 ppm Helps dissolved wine to remove of

oxygen

PLANT LAYOUT & DESIGN OF WINERY

4.0) Plant layout:

The plant layout of N.D wines is as given below in drawing form

Tank Hall no.1 Specifications:

Tank capacity Height(cm) Inside Dia.(cm) Drip volume 2000 ltr. 177.4 119.5 76.3 ltr. 5000 ltr. 277 149.8 82.5 ltr. 2.7 7.0 7000 ltr. 227.5 200.1 84.8 ltr. 2.9 7.0 10,000 ltr. 249.7 225.6 71.3 ltr. 3.0 7.4 14,000 ltr. 293 249.3 73 ltr. 3.2 7.4 15,000 ltr. 300.5 250.2 74.2 ltr. 3.4 7.5 20,000 ltr. 329.4 250.8 85.4 ltr. 3.4 8.0

2.7 Shell thickness(mm) 6.9 Height from Datum (cm)

Total capacity: 474 KL Total no. of Tanks: 46 Tanks Area: 70*70 sq.ft Height of floor to roof:

Tank Hall no.2 Specifications:

Total No. of Tanks: 21 Capacity: 17,000 ltr. Total Capacity of Tanks: 357 KL Area of Hall: 25*108 sq.ft Internal Dia. Of Tanks(cm): 329.3 Shell thickness: 3 mm Height of Tanks (cm): 320.7 Height floor to roof (cm):

4.1 Introduction to Plant design:

4.1.1General principles The design of a process plant is a complex activity that will usually involve many different disciplines over a considerable period of time. The design may also go through many stages from the original research and development phases, through conceptual design, detailed process design and onto detailed engineering design and equipment selection. Many varied and complex factors including safety, health, the environment, economic and technical issues may have to be considered before the design is finalised . At each stage it is important that the personnel involved have the correct combination of technical competencies and experience in order to ensure that all aspects of the design process are being adequately addressed. Evidence of the qualifications, experience and training of people involved in design activities should be presented in the Safety Report to demonstrate that the complex issues associated with design have been considered and a rigorous approach has been adopted. The process design will often be an iterative process with many different options being investigated and tested before a process is selected. In many occasions a number of different options may be available and final selection may depend upon a range of factors. The process design should identify the various operational deviations that may occur and any impurities that may be present. In the mechanical design, the materials of construction chosen need to be compatible with the process materials at the standard operating conditions and under excursion conditions. The materials of construction also need to be compatible with each other in terms of corrosion properties. Impurities which may cause corrosion, and the possibility of erosion also need to be considered so that the detailed mechanical design can ensure that sufficient strength is available and suitable materials of construction are selected for fabrication. 4.1.2 Codes and Standards Modern engineering codes and standards cover a wide range of areas including:

Materials, properties and compositions; Testing procedures; for example for performance, compositions and quality; Preferred sizes; for example for tubes, plates and standard sections; Design methods and inspection and fabrication; Codes of practice for plant operation and safety.

4.2 Production facilities

This section summarises the facilities needed in a wine making processing unit (winery).

4.2.1 Plant location

Because fresh grapes are bulky and spoil rapidly, it is better to locate a processing unit in the area where they are grown. This reduces transport costs and also reduces the amount of handling, which means that crops are more likely to be in good condition when they arrive at the processing unit. If they are in good condition, they can be stored for a few days before they have to be processed. Too much handling bruises them and they will spoil quickly. This increases the cost to the processor, because the spoiled food has already been paid for. Pro cessed wines products are likely to be sold in different markets and there is less reason to locate the unit near to customers. An ideal site is close to a grapes growing area( near Nasik) and near to a main road leading to an urban centre. The location of the processing unit in a rural area means that there may be problems with: Reliable electricity Adequate supplies of potable water. Contamination of supplies Access for workers and staff (public transport, distance down an access road) Quality of the road (dry season only, potholes that may cause damage to glass containers) Absence of other facilities (e.g. schools, medical facilities, shops and entertainment) that make working there less attractive than an urban location Each of these should be assessed before choosing a site. In rural locations there is usually more land available for waste disposal compared to urban sites, but there may be problems caused by insects and birds or straying animals getting into the building. It is therefore important to have a site with cleared and fenced land, preferably having short grass, which helps to trap airborne dust.

4.2.2 The building

All wineries businesses should have a hygienically designed and easily cleaned building to prevent contamination of products. Buildings in rural areas may cost more to construct because

of higher transport costs for building materials, but rents in rural areas are usually lower than urban centres. The investment in construction or the amount of rent paid should be appropriate to the size and expected profitability of the business. Within the building, food should move between different stages in a process without the paths crossing (Fig). This reduces the risk of contaminating finished products by incoming, often dirty, crops, as well as reducing the likelihood of accidents or of operators getting in each others way. There should be enough space for separate storage of raw materials, away from ingredients, packaging materials and finished products.

4.2.3 Roofs and ceilings

Overhanging roofs keep a building cooler, this is especially important when processing involves heat. Fibre-cement tiles provide greater insulation than galvanised iron sheets against heat from the sun. Roof vents allow heat and steam to escape and create a flow of fresh air through the processing room. The vents must be screened with mesh to keep insects and birds out of the room. If heat is a serious problem (e.g. fermentation), electric fans or extractors can be used if they are affordable. A panelled ceiling should be fitted in processing and storage rooms, rather than exposed roof beams, which allow dust to accumulate and fall off in lumps and contaminate products. Beams are also paths for rodents and birds, creating contamination risks from hairs, feathers or excreta. It is important to ensure that there are no holes in the panelling or in the roof and no gaps where the roof joins the walls, which would allow birds, rodents and insects to enter.

4.2.4 Walls, windows and doors

All internal walls should be plastered or rendered with concrete. The surface finish should have no cracks or ledges, which could harbour dirt or insects. The lower parts of the walls are most likely to get dirty from washing equipment, product splashing etc. They should either be tiled, or painted with waterproof white gloss paint to at least one and a half metres above the floor. Higher parts of walls and the ceiling can be painted with good quality white emulsion paint. Natural daylight is preferable to and cheaper than, electric lighting in processing rooms. The number and size of windows depends on the amount of money that a processor wishes to invest and the security risk in a particular area (windows are more expensive than walls, especially

when security bars or grilles are needed). Storerooms do not need to have windows. Open windows let in fresh air, but this also provide easy access for flying insects. All windows should therefore be screened with mosquito mesh. Windowsills should be made to slope to prevent dust accumulating and to prevent operators leaving cleaning cloths or other items lying there, which can attract insects. Storeroom doors should not have gaps beneath them and should be kept closed to prevent insects and rodents from getting in and destroying stocks of product, ingredients or packaging materials. Processing room doors should be kept closed unless they are fitted with thin metal chains, or strips of plastic or cloth hung from door lintels. These keep out insects and birds, but allow easy access for staff. Alternatively, mesh door screens can be fitted.

4.2.5 Floors
Floors in processing rooms and storerooms should be made of good quality concrete, smooth finished and without holes or cracks. Over time, spillages of acidic fruit products react with concrete and erode it. Paints can protect floors, but vinyl-based floor paints are expensive. Red wax household floor polishes should not be used because they wear away easily and could contaminate products or spoil the appearance of packages. The best way to protect floors is to clean up spillages as they occur and make sure that the floor is thoroughly washed after each days production. Dirt can collect in corners where the floor and the walls join. To prevent this, the floor should be curved up to meet the wall. The floor should also slope to a drainage channel. Proper drainage prevents pools of stagnant water forming, which would allow insects to breed. The drainage channel should be fitted with metal gratings that are easily removed so that the drain can be cleaned. Rodents and crawling insects can also get into the building through the drain and a wire mesh cover should be fitted over the drain opening. This too should be easily removed for cleaning.

4.3 Services 4.3.1 Lighting and power

Where lighting is needed, florescent tubes use less electricity than light bulbs. Electric power points should be located at least one metre above the floor so that there is no risk of them getting wet when the floor and equipment is washed down. Ideally, waterproof sockets should be used.

Each power point should only be used for one machine. Multiple sockets should not be used because they risk overloading a circuit and causing a fire. All plugs should have fuses that are appropriate for the power rating of the equipment and the mains supply should have an earth leakage trip-switch. Cables should be properly fixed to walls or run vertically from the ceiling to machines. There should be no exposed wires at any connection. Electric motors should be fitted with separate starters and isolators.

4.3.2 Water supply and sanitation

Potable water is essential in all winery , as an ingredient in some products and for washing down equipment. An adequate supply of potable water should be available from taps in the processing room. If there is no mains supply, or if the mains supply is unreliable or contaminated, water from boreholes is likely to be relatively free from microorganisms, but it may be contaminated with sand. River water is likely to be contaminated and should only be used if no other source is available. Samples of water should be periodically checked (e.g. once per year) for contamination by micro-organisms at the Bureau of Standards. To remove sediment, two high level covered storage tanks should be installed, either in the roofspace or on pillars outside the building. They are filled when mains water is available or with water pumped from boreholes. While one tank is being used any sediment in water in the other tank settles out. The capacity of each tank should be enough for one days production. The tanks should have sloping bases and be fitted with drain valves at the lowest point to flrs. Out any sediment that has accumulated. If necessary, water should be treated to remove micro-organisms. There are four ways of treating water at a small scale: by filtration; by heating; by ultra-violet light and by chemical sterilants, such as hypochlorite (also known as chlorine solution or bleach). Domestic water filters are too slow for the large amounts of water required and other water treatment methods are likely to be too expensive for small-scale producers. Micro-organisms can also be destroyed by boiling water for 10-15 minutes, but this is not realistic for large volumes because of the high fuel costs and the time required to do this each day. Also, boiling does not remove sediment and boiled water may also need to be filtered. Ultra-violet light destroys micro-organisms in water and commercial treatment units are suitable for processors that use a lot of water. Again, this method does not remove sediment.

Dosing water with bleach is fast, cheap and effective against a wide range of microorganisms. Water for cleaning should contain about 200 ppm of chlorine (by mixing 1 litre of bleach into 250 litres of water). Water that is used as an ingredient should not contain more than 0.5 ppm chlorine (by adding 2.5 ml of bleach to 250 litres of water), to avoid contaminating products with a chlorine smell. Care is needed when using bleach because it damages the skin and particularly the eyes and can cause breathing difficulties if inhaled. It also corrodes aluminium equipment. Equipment should be thoroughly cleaned after each days production, using a cleaning routine that is clearly understood and followed by production workers (see Section 6, Quality Assurance). Solid wastes should be placed in bins and removed from the building at intervals, rather than letting them accumulate during the day. Wastes should never be left in a processing room overnight. Wastes should be taken far away from the processing site and either buried or turned into compost. Large volumes of liquid wastes are created in wine processing and these should be carefully disposed of to prevent local pollution of streams or lakes. If mains drainage is not available, a soak-away should be constructed in a place that cannot contaminate drinking water supplies. Water should not be allowed to simply soak into the ground, because this will create swampy conditions, which attract insects that contaminate products, as well as introducing a health hazard. Toilets should be separated from the processing area by two doors or be located in a separate building. Workers should have hand-washing facilities with soap and clean towels. A summary of the basic rules on hygiene and sanitation.

4.4 Basic rules for hygiene and sanitation in wine making: 4.4.1 Facilities required in the processing room
A changing room where clothing and shoes that are not worn for work can be stored. Separate hand-washing facilities for staff, with soap, clean water, nail brrs.es and Clean towels. Toilets, which should be separated from the processing room by two doors or located In a nearby building. First aid materials.

Protective aprons or coats washed regularly, hats/hairnets and if necessary, gloves and shoes. Cleaning chemicals, stored away from the processing room.

4.4.2 Ways of working

Clean the processing room, toilets, washing facilities and storerooms every day Use the correct chemicals to clean equipment, make sure there are no food residues and rinse the equipment with clean water. Make sure all cleaning cloths are washed and boiled each day. Do not hang them on equipment, or put them on products or window ledges to dry. Do not leave dirty equipment until the end of the day before cleaning it. Keep the area around the processing room clean and tidy. Keep grass cut short. Put all wastes into bins that are not used for anything else. Empty the bins periodically during the day away from the processing site. Clean up any spillages as they occur. Prevent all animals from entering the processing area or storerooms. Visitors should only enter the processing room wearing protective clothing and under supervision. Do not wear clothing or jewellery that can get caught in machinery. Wear a hat that completely covers the hair. Do not comb your hair in a processing room or storeroom. Cover all cuts, burns and sores with a clean, waterproof dressing. Do not handle any food if you have sores, boils, septic spots, a bad cold, sore throat or a stomach upset. Report any of these to the manager and do alternative work Do not smoke or eat in any room where there is open food because bacteria can be transferred from the mouth to the food. Do not spit in a processing room or storeroom. Wash hands and wrists thoroughly with soap after using the toilet, eating, smoking, coughing, blowing your nose, combing your hair, handling waste food, rubbish or Cleaning chemicals. Dry them on a clean towel before handling food again. Keep fingernails cut short.

Do not wear perfume or nail varnish as these can contaminate products. Do not cough or sneeze over food. Keep food covered wherever possible. Keep all food, tools and equipment off the floor. Keep ingredients in sealed containers. Do not use broken or dirty equipment. Report any signs of insects, rodents or birds to the manager

4.4.3 Production planning

Production planning involves thinking ahead to make sure that everything is in place to produce the required amount of wines. Inadequate planning causes stoppages in production because for example, not enough fruit is bought, an ingredient is used up, or there are not enough staff to produce the required amount of product in the time available. The short harvest season for many raw materials means that everything must be in place and working properly at the start of the harvest so that enough crop can be processed to produce sufficient product for the following year. The amount of less perishable ingredients, such as Active dry yeast, KMS, bentonite, CO2 and packaging materials that are stored as stock depends on a number of factors: A large amount of stock ties up cash while it is waiting to be used. Some stock deteriorates over time and money is lost due to spoilage If processors buy smaller quantities more often, this is more expensive than buying in bulk.

Decisions on stock levels therefore depend on the cost and reliability of supplies, their shelf life and the amounts that are used each day. If production stoppages happen too frequently, the amount of product available for sale falls to a level where the business cannot afford to pay the bills and it fails. Successful business people manage their cash flow, so that enough money is available to buy the inputs needed for production, before income is received from the sale of products. To do this they plan their production carefully. Careful production planning is used to find the:

1. Number of workers required and their different jobs 2. Equipment needed to achieve the planned production level 3. Weights of raw materials and ingredients to be bought 4. Number of packages required 5. It can also identify any bottle-necks in the process. Production can be planned using the calculations. The information required to do this includes: How much product (kg or litres) is sold (not made) each month? How many hours are worked per day? How many days are worked per month? This information is first used to calculate the daily production rate, so that ingredients and packaging can be ordered. Then the average amount of production per hour (termed product throughput) can be calculated to find the size of equipment and numbers of workers required.

4.4.5 Daily production rate

The daily production rate is calculated as follows:

This figure is used to decide how much raw material, ingredients and packaging to buy. One of the main causes of error is to over-estimate the number of working days, particularly if there are regular power failures or if staff is often absent.

4.4.6 Packaging
When selecting packaging materials, the processor should consider: Technical requirements of the product (for protection against light, crushing, air, moisture etc.) The design (for promotional and marketing requirements) The relative cost and availability of different types of packaging. Packaging is often the biggest problem for small-scale processors in India and advice should be sought from food technologists or agents of packaging manufacturers. New glass jars and bottles are available in market. Because of their heavy weight, high bulk and fragility, they are

expensive to transport and breakages can be high if they are not properly packed. There are also minimum order sizes, which may be too high for individual small-scale processors. Re-used bottles for local market are collected and sold in India , but great care is needed to ensure that they are properly cleaned, because they may have been used to store chemicals, such as pesticides or kerosene. This is time-consuming, but bottle cleaners and rinsers can be constructed to save time and labour costs.

4.4.7 Equipment and Machineries

The throughput figure allows the processor to decide the size and/or number of pieces of equipment that are required. In doing this, decisions need to be taken on the benefits of employing a larger number of workers or buying a machine to do a particular job. Equipment used in wineries are Press machine, Destemmer, Fermentation tanks and storage tanks, racking pumps, pumpover, autoclave, bottling and corking machine etc. The size of equipment and machineries are depends upon production planning, capacity of wine making.

4.4.8 Staff
The numbers and types of workers needed to operate a wine processing business depend on the amount of production and also on the degree of mechanisation of the process. This type of processing is more seasonal than many other types and temporary staff is commonly employed during harvest times. Machinery such as a pulper finisher for juice preparation, fermentation, racking or machines for filling and corking wine bottles, can significantly reduce the numbers of workers needed. However, a processor needs to carefully compare the cost of labour with the cost of maintenance, spare parts and possibly loan repayments from buying the equipment to see which is most cost-effective. When deciding the number of people needed to produce a particular amount of product, the process charts in Section 4 can be used to break down a process into different stages. A decision can then be taken on whether a particular stage can be done manually and the number of people who will be needed, or whether a machine will do the work. It is important also to include work such as store management, quality assurance and bookkeeping when planning the number of staff members that are needed.

It is possible to have all workers doing the same type of work throughout the day (e.g. everyone prepares stemmed grapes together then moves on to load a dpress machine and then all packing of aged wines bottles the previous days production). However, it is often more efficient to allocate different jobs to each worker as the day progresses. A convenient way of planning this is to draw an Activity Chart . This shows the type of work that is to be done each hour during the day, the number of people involved and the sequence of work that individuals do during the day. This type of chart can also be used to train workers in each of the different jobs in a process.

4.5 Health and safety

All processors have a responsibility to provide safe and healthy working conditions for their staff. In wine processing the main dangers are as follows:

4.5.1 Damage to skin

When workers handle raw grapes and handling of packaging material,during cleaning of tank halls, machineries they should wash their hands regularly or be provided with thin gloves to prevent skin damage from cleaning agents. In particular, care is needed with grapes, which contain an enzyme that attacks the skin. Care is also needed when handling bleach to avoid damage to the skin.

4.5.2 Burns and cuts

Aprons or coats and heat resistant gloves should be provided and staff should be trained to handle such foods safely . There are also dangers of cuts from sharp blades on motorised cutters or liquidisers. Staff should be properly trained to use machines safely, particularly when cleaning them and workers should not wear cloths or jewellery that could become tangled in moving equipment.

4.6 Record Keeping

There are four sets of records that should be kept by the owner of a small fruit and vegetable processing unit:

1. Financial records 2. Production records 3. Quality assurance records 4. Sales records. 5. Excise Records As with other inputs to a business, keeping records is an investment of time and money and this must be related to the scale and profitability of the business (the benefits must outweigh the costs).

Records must be used for them to have any value.

This means that the processor must understand why the information is collected and what it can be used for. Processors should also put in place a system of checks to ensure that one person does not have responsibility for a whole area of record keeping. For example the person who keeps records of purchases should be different to the person who records levels of stocks and manages the storeroom.

Table 4 .1 Types of records for wine processing business

Type of record Production records Information to be recorded Methods for red and white wine making Raw materials and ingredients received and suppliers Wastage % at different stages of the process Stock levels for each ingredient Production volumes and measurements Maintenance programs and schedules Target amounts of ingredients and any changes made to recipe Measurements made at process control points Batch numbers and product code numbers Cleaning procedures and schedules Names of customers and amounts sold to each Weekly and monthly sales volumes Income from sales Costs of all process inputs Staff records Cash flow Profit/loss

Quality assurance Records

Sales records Financial records

Tax records Bank statements

Evaluation card no. 1

Question 1. Do you know how to calculate your production rate? 2. Do you know how to calculate the amounts and true costs of ingredients required for a given production rate? 3. Do you know how to plan labour requirements and how to allocate jobs to different workers to maximise efficiency? 4. Do you have correct maintenance procedures for your equipment? 5. Do you keep adequate records? Yes No or Notes if required

5.0 Equipment Cost estimation of Winery Table: 4.2

Sr.no 1. Equipment/machinery Wine fermentor and storage tanks 2. 3. 4. 5. 6. 7. 8. 9. 10. Destemmer Press machine Racking pumps Micofilter Bottling machine Temp. sensor Temp. control panel Chilling plant Gaskets 1 2 5 2 set 1 70 1 set 1 200 7 Lakh 45 lakh 20,000 9,000 6.5 Lakh 3750 5000 35 lakh 5000 Quantity 75 Tanks Estimated cost 2.4 Cr.

11. 12. 13. 14. 15.

Water treatment Weigh lifter K-type wine filter Racking pipes Plant piping

1 1 1 10

60,000 20,000 2.5 lakh 1 lakh 10 lakh

5.1 Laboratory material cost: Table:4.3

Sr.no 1. Material Hand refractometer 2. 3. 4. 5. 6. Hydrometer pH meter Torque meter So2 assembly Volatile acidity assembly 7. 8. 9. Ebulliometer Thermometer Distillation water unit 10. Analytical weigh balance 11. Pipette 10 250 Measurement of sample 12. 13. 14. 15. 16. 17. 18. 19. Burette & stand Weigh balance Test tubes Microfilter Injection Heating coil Conical flask Beaker 4 1 10 1 2 1 5 4 350 2000 150 300 100 5000 150 150 titration For weighing analysis Filteration of wine sample To heat the sample For taking sample For sample 1 55,000 Micro weighing 1 2 1 20,000 500 1500 Alcohol estimation Temp. Distilled water 1 1 1 1 1 5000 4500 150 2000 1500 analysis analysis Density check pH Quantity 2 Estimated cost 1000 Use
0

brix

measurement

20. 21.

Test tube stand Chemicals for analysis

3 15

100 8000 For laboratory analysis

22. 23.

Computer Record files

1 5

25000 200

For record keeping For record keeping

5.2 Land & Infrastructure cost:

Land Purchased cost: 1.2 crore Land area: 9900 sq. ft

Infrastructure build up cost: ( constru material + labor cost)= (70 lakhs + 25 lakhs) = 95 lakhs Water supply boring cost: 3.5 lakhs Digital Generator cost: 20.5 lakhs Land & Infrastructure total cost: 23,900,000 INR

Excise License fees: 31000 INR. 6.0 Capital Investment of Winery plant: Installed Capacity 10 Lakh Ltr.
A.Land & Infrastructure cost: 23,900,000 B. Excise License Fees: 31,000 INR C.Plant Equipment & machinery cost: 3,48,22,750 INR D.Laboratory cost : 1,32,900 INR

Total Capital Investment: ( A+B+C+D)= (23,900,000 + 31,000 + 3,48,22,750 + 1,32,900) = 58,886,650 INR ( ESTIMATED)

7.0 Total Production Cost:

Material Balance of Process flow sheet

Receiving of Harvested Grapes( 1000 kg)

Destemming/Crushing

Pomance 320 kg.

Chilling & Settling 650 kg juice Racking

Residue 20 kg

Fermentation

CO2

Racking

Clarification & Stablization

Residue 10 kg.

Storage

Blending(optional)

Filteration

Bottling

Corking,Labelling & Packaging

Basis: 1 litre of 13.5% w/w ethanol in wine Input of grapes = Output + Accumulation 1000 kg = output ( wine) + (320+20+10) kg. Output of wine = 650 kg or 650 litre wine

Table: 4.3
Manpower Production Wine aging Operator Maintenance Quantity 30 10 3 1 Duration 5 months 7 months 12 months 12 months Payskill/ person 3500 INR 4000 INR 6000 INR 6000 INR

Table: 4.4
Administration Manager Production manager Accounts Winemaster Quantity 1 1 2 1 Duration 12 months Payskill/person 25,000 INR 25000 9000 6 Lakhs

Electricity charges per annum: 10 lakhs Raw material cost: Wine Grapes : Amount: 900 ton Cost: 2.25 crore

Yeast: S.cerevisiae Amount: 100 kg. Cost: 3000/kg Oak chips & Chemicals: Cost: 4.5 Lakhs Raw material total cost: 2.33 cr. Manpower cost per annum: 10.93 Lakhs Administration cost: 79.92 Lakhs Total Production Cost: (Electricity Charges + Raw material cost + Manpower cost + Administration cost) = ( 10 lakhs + 2.33 cr. + 10.93 lakhs + 79.92 lakhs) = 3,42,22000 INR Production cost/ litre ( bulk wine): Total Production cost/ annual production = 3,42,22000/ 6,00000 ltr. = 57.036 INR/ltr of Bulk wine

4.0 RESULT AND DISCUSSION

I worked at the N.D Wines Pvt. Ltd, India as the PRODUCTION TRAINING and learnt the process of Wine making Process Technology and Plant design of winery. Their implementation on the site as well as the preparation of the supporting documents of Capital Investment. Plant Design is made up of three components:1. Documentation - Tells us what to do and how to do it. 2. Plant Layout It includes the representation of each section of plant and it;s Design 3. Cost Evaluation Estimating the capital investment, Production cost and where improvements will be made.

The design of a process plant is a complex activity that will usually involve many different disciplines over a considerable period of time. The design may also go through many stages from the original research and development phases, through conceptual design, detailed process design and onto detailed engineering design and equipment selection. Many varied and complex factors including safety, health, the environment, economic and technical issues may have to be considered before the design is finalised . I have completed all the documents (Plant layout, SOPS. Hygiene & Sanitation, CIP sheet, cost analysis etc), Designing of Training module, conducting training, physical inspection plan, compliance monitoring, etc

Glossary and Acronyms

Acid preserves Adulteration Brix Case hardening Chlorination Contamination Critical control Cross contamination Enzymes Foods that have a high acid content that inhibits spoilage. Deliberate contamination of foods with materials of low quality. Units of measurement of sugar concentration The formation of a dry skin on a wet food due to over-rapid drying. It slows the rate of drying and can lead to spoilage during storage. The addition of chlorine to water to destroy micro-organisms. Materials that are accidentally included with a food (e.g. dirt, leaves, stalks etc.). Stages in a process where quality control can have a major effect Points on food quality or safety.

The transfer of soils or micro-organisms from raw food to processed food Natural proteins in foods that can cause changes to colour, flavour or texture of the food. FIFO First in, first out inventory scheme for raw materials and finished products. Fill-weight The amount of food placed into a container or package and written on the label (also net weight). Humidity The amount of water vapour in air. Hydrometer An instrument that measures specific gravity of liquids, used to measure salt,sugar or alcohol concentration. Low-acid Foods foods that have little acid and therefore can contain food poisoning bacteria if poorly processed. Minimum weight All packages have a fill-weight equal to or greater than that shown on the label. Net weight The amount of food filled into a container. Pectin A natural gelling agent found in some fruits pH A scale used to express acidity or alkalinity, from 1 (strong acid) through 7 (neutral) to 14 (strong alkali). Potable water Clean and wholesome water that will not cause illness. Preservation Index a figure that is calculated to show that the amounts of acid, sugar and salt are enough to prevent spoilage of foods. Quality assurance A management system which controls each stage of food production from raw material harvest to final consumption. Refractometer An instrument that measures the refractive index of a liquid, which is used to measure soluble solids in syrups or salt in brines. Shelf life The time that a processed food can be stored before changes in colour, flavour, texture or the number of micro-organisms makes it unacceptable. Sodium benzoate A chemical preservative that is particularly effective against yeasts. Sodium metabisulphite A chemical preservative that is effective against moulds and yeasts.

Acronyms
CCP FIFO GHP GMP HACCP ROPP TOTO UHT Critical Control Point First in, First out inventory control system Good Hygienic Practices Good Manufacturing Practices Hazard Analysis Critical Control Point system Roll on Pilfer Proof (caps for bottles) Twist on Twist off (lids for jars) Ultra-High Temperature (sterilisation of foods)

5.0 References/Literature Cited: 1. Plant Design & Economics edited by Max S.Peter, Klaus D. Timmerhaus 2. Food Plant Economics Zacharias B.Maroulis , George D.Saravacos 3. Wine tech engineers Pvt.Ltd. 4. Seepra refrigeration Pvt. Ltd. 5. www.winemaking.co.nz